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设计了某预制坯形状下的铁座多向锻造成形工艺,通过工业试验得到了铁座样件,针对铁座零件在多向锻造成形过程中产生的折叠、毛刺等缺陷的产生原因进行了分析。通过建立有限元模型,选择合理的模拟参数,采用Deform体积成形软件对铁座多向锻造成形工艺过程进行数值模拟,并结合Deform软件后处理中的点跟踪功能对成形过程中金属的流动规律进行了有限元分析。结果表明:铁座样件粗大毛刺产生的根本原因是试验模具结构设计不合理导致的成形上模合模力剧增,增加量高达3776.82 k N,成形载荷超出了设备的能力范围,使模具在成形过程中未完全打靠;铁座折叠缺陷产生的临界压下量为14 mm,试验过程中9 mm的压下量不足以产生折叠缺陷,折叠缺陷产生的根本原因是热态下铁座预制坯两侧体积块与上模的初始装配间隙过小,上模下行与预制坯一接触便产生了干涉。针对铁座样件缺陷产生原因的分析提出了解决方案,并在模拟条件下得到了成形良好的铁座锻件,验证了预制坯形状的合理性及成形工艺的可行性。
The multi-direction forging forming process of the iron seat under a preform shape was designed. The iron seat samples were obtained through industrial experiments. The causes of the defects such as folding and burrs produced in the multi-direction forging process of the iron seat parts were analyzed . Through the establishment of finite element model, select reasonable simulation parameters, the use of Deform volume forming software for multi-direction forging iron forming process for numerical simulation, combined with Deform software in the post-processing point tracking function of the metal flow in the forming process Finite element analysis. The results show that the basic reason for the gross burrs on the iron-base specimen is that the mold-forming force of the forming mold increases sharply due to the unreasonable design of the mold structure. The increase amount is as high as 3776.82 kN, the forming load is beyond the scope of the equipment, The forming process is not fully hit; the critical reduction of the iron seat folding defects is 14 mm, the reduction of 9 mm during the test is not enough to produce the folding defects. The root cause of the folding defects is that the iron seat is prefabricated Billet on both sides of the block and the initial assembly of the upper die gap is too small, the lower die and the preform down a contact will have interference. Aiming at the analysis of the cause of the iron-base specimen defects, a solution was proposed and a well-formed iron seat forging was obtained under the simulation conditions to verify the rationality of the preform shape and the feasibility of the forming process.