模具加载方式对不规则阀体多向模锻工艺的影响

Influence of die loading mode on multi-directional die forging process for irregular valve body

为提高一种复杂不规则阀体的性能和生产效率,设计了一种多向模锻生产工艺,并通过建立高温下的材料压缩仿真模型和多向模锻有限元分析模型,利用Deform-3D软件模拟了不规则阀体的成形过程,分析了不同模具加载方式对阀体成形结果、阀体温度分布、各凸模载荷变化、最小合模力以及各模具温度的影响。结果表明:第1种加载方式成形困难,容易产生毛刺和锻造不满等缺陷,第2种加载方式易产生折叠缺陷,而第3种、第4种加载方式可有效避免成形缺陷,并且第4种加载方式对提高阀体质量和模具寿命更有利。最后,利用多向模锻液压机进行了各加载方式下的阀体成形试验,通过试验与模拟对照验证了分析过程的准确性,同时,在合适的工艺下获得了表面平滑、尺寸合格、纤维流线均匀且无折叠、毛刺等缺陷的阀体锻件,该研究能有效推动各类阀体生产工艺的发展。

In order to improve the performance and production efficiency of a complex irregular valve body,a multi-directional die forging production process was designed,and through establishing a material compression simulation model and a multi-directional die forging fi-nite element analysis model at high temperature,the forming process of irregular valve body was simulated by software Deform-3D,and the influences of different mold loading methods on forming results of valve body,temperature distribution of value body,load changes of vari-ous punches,minimum clamping force and various mold temperatures were analyzed.The results show that the first loading mode is diffi-cult to form,and is easy to produce burr and incomplete forging defects,the second loading mode is easy to produce folding defect,while the third and fourth loading modes can effectively avoid forming defects,and the fourth loading mode is more beneficial to improve the valve body quality and the mold life.Finally,the valve body forming tests under various loading modes were carried out by the multi-di-rectional die forging hydraulic press,and the correctness of the analysis process was verified through the comparison between the test and simulation results.At the same time,the valve body forgings with smooth surface,qualified size,uniform fiber streamline and without de-fects such as folds and burrs were obtained under the appropriate process.Thus,this research can effectively promote the development of various valve body production processes.