摘要
针对某型汽车铝合金空气悬挂支撑臂模锻成形过程中出现的折叠缺陷,结合数值仿真与生产工艺优化开展了研究。通过Forge软件模拟锻造成形过程,分析金属流动特性发现,折叠缺陷成因主要为模具过渡圆角半径过小及坯料摆放位置不当引发的金属回流与对冲。为此提出模具圆角优化和调整坯料摆放位置两个优化方案,仿真结果表明:将分模面处的模具圆角半径由R3 mm增加至R8.5 mm并加宽桥部,可以使折叠区域转移至飞边;调整坯料摆放位置,使其沿模具型腔曲率倾斜,可以优化金属流动路径,消除型腔内的金属汇流,从而完全消除折叠缺陷。最后,经实际生产验证,优化后锻件质量得到显著提升,为复杂铝合金部件的锻造工艺改进提供了有效方法。
For the folding defects that occurred during the die forging process of aluminum alloy air suspension support arm for a certain type of automobile,combining numerical simulation and production process optimization,the forging forming process was simulated by Forge software,and the metal flow characteristics were analyzed.Then,it was revealed that the main cause of folding was the metal reflux and hedging caused by the small transition fillet radius of die and the improper placement of billet,and two optimization schemes were proposed,namely,optimizing the die fillet and adjusting the placement position of billet.The simulation results show that increasing the die fillet radius at the parting surface from R3 mm to R8.5 mm and widening the bridge can transfer the folding area to the flash.Adjusting the placement position of billet to make it tilt along the curvature of die cavity can optimize the metal flow path and eliminate the metal confluence in the cavity,which can completely eliminate the folding defects.Finally,verified by the actual production,the quality of forgings is significantly improved,which provides an effective method for improving the forging process of complex aluminum alloy parts.
作者
曹腾
章科举
陈钰金
金康
张波
Cao Teng;Zhang Keju;Chen Yujin;Jin Kang;Zhang Bo(Anhui Wangjin Automotive Parts Co.,Ltd.,Xuancheng 242399,China;China Academy of Machinery Beijing Research Institute of Mechanical&Electrical Technology Co.,Ltd.,Beijing 100083,China;China Machinery Industry Technology Research Institute of Precision Forming,Wuhu 241000,China)
出处
《锻压技术》
北大核心
2025年第5期57-63,共7页
Forging & Stamping Technology
关键词
铝合金
悬挂支撑臂
折叠缺陷
锻造工艺
模具优化
aluminum alloy
suspension support arm
folding defect
forging process
die optimization
