摘要
针对发动机齿轮轴锻件超声波探伤检测出的折叠缺陷,提出了物理实验与有限元数值模拟技术相结合的研究方法。对产生缺陷的样件进行剖切,观察试样剖切面的折叠位置和折叠情况。根据折叠的宏观形貌和发生部位分析缺陷产生原因,采用Deform-3D有限元数值模拟验证所做的理论分析,并依据金属塑性成形理论中的体积不变原理,优化齿盘部纵横向上相关联的预成形上模模具厚度尺寸:在尺寸变化最大处,锻件盘部结构的纵向厚度最大减小了2 mm,圆弧部分横向厚度最大减小了6 mm,确保能够增加一个高17 mm的类蘑菇头结构,达到消除折叠缺陷和保证生产锻件合格的目的。对改进后的模具结构,采用Deform-3D软件二次分析其成形过程来保证模具结构优化后的合理性和可靠性,在消除缺陷的前提下确保预终锻工艺能够连续正常生产出合格锻件。最后,对批量生产的锻件进行抽样探伤以及内部金属流线检验。
Aiming at the fold defects of engine gear shaft forgings tested by ultrasonic flaw detection,a research method combining physical experiment with finite element numerical simulation technology was proposed.The defective sample was cutted and the folding position and folding situation of the cut surface of the sample were observed.The causes of defect were analyzed according to the macroscopic shape and location of the folding,and the theoretical analysis was verified by Deform-3D finite element numerical simulation.According to the volume invariance principle in the metal plastic forming theory,the thickness of correlative preformed upper mold in the longitudinal and transverse directions of the toothed disc was optimized:the longitudinal thickness of the forging disc is reduced by a maximum of 2 mm,while the transverse thickness of the circular part is reduced by a maximum of 6 mm in positions with the largest size changes,ensuring that a 17 mm high mushroom head like structure can be added to eliminate the folding defect and guarantee the production of qualified forgings.For the improved mold structure,the rationality and reliability of the optimized mold structure were ensured by the second analysis of the forming process based on Deform-3D,and the qualified forging parts are ensured to be producted continuous and normally by pre-finish process under the premise of eliminating the defects.Finally,flaw detection and internal metal streamline inspection of the mass production forging parts were performed.
作者
何伟
董万鹏
孙礼宾
朱越
张震
HE Wei;DONG Wan-peng;SUN Li-bin;ZHU Yue;ZHANG Zhen(College of Materials Engineering,Shanghai University of Engineering Science,Shanghai 201620,China;Shanghai Collaborative Innovation Center of Laser Advanced Manufacturing Technology,Shanghai 201620,China;Shanghai JD Chukyo Forging&Stamping Co.,Ltd.,Shanghai 201414,China)
出处
《塑性工程学报》
CAS
CSCD
北大核心
2019年第6期42-49,共8页
Journal of Plasticity Engineering
基金
国家自然科学基金资助项目(31670956)
上海工程技术大学研究生科研创新项目(18KY0506)
