| 摘要: |
| 针对某种2A12铝合金车用连接锻件质量差,容易报废的问题,利用Deform仿真系统对该锻件的变形过程进行了模拟分析。根据模拟结果可知,锻件易报废是由于材料相对流动产生折叠引起的。鉴于此,在原工艺基础上增加了预锻工序,预成形后有效消除了材料的折叠缺陷。但同时又出现了锻件顶部枝叉充不满的缺陷,因此对锻模进行了优化,引入了阻力沟及阻力墙结构。研究了两种飞边槽结构对充填过程改善情况、成形力变化的影响,并联合实际锻造实验进行了验证。结果表明:采用阻力沟结构,充不满缺陷仅能得到改善,并不能完全解决；而采用阻力墙结构,对预锻后的毛坯进行锻造后,能得到充填饱满,无折叠缺陷的锻件,成功地解决了原工艺存在的问题。 |
| 关键词: 2A12铝合金 折叠缺陷 预锻 充不满缺陷 工艺优化 飞边槽 |
| DOI：10.11951/j.issn.1005-0299.20210272 |
| 分类号:TG316；O242.21 |
| 文献标识码:A |
| 基金项目: |
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| Deformation analysis and process design of 2A12 aluminum alloy connecting forgings for vehicles |
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ZHANG Wei
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(Institute of Intelligent Manufacturing,Zhengzhou University of Economics and Business,Zhengzhou 450007,China)
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| Abstract: |
| To tackle the problems of poor quality and easy scrapping of a type of 2A12 aluminum alloy connecting forging for vehicles, the deformation process of the forging was simulated and analyzed by using the Deform simulation system. Simulation results show that the folding defect induced by the relative flow of the materials caused the easy scrapping of the forging. In view of this problem, the pre-forging process was introduced on the basis of the original process, which could effectively eliminate the folding defects of the materials after pre-forming, whereas the defect of insufficient filling of branches and forks occurred on the top of forging. Thus, the forging die was optimized, and the structures of resistance ditch and resistance wall were proposed. The influences of the two kinds of flash groove structures on filling improvement and forming force change were analyzed, and then verified by combining with actual forging test. Results show that by using the resistance ditch structure, the filling defects were only improved, but could not be completely solved. While with the introduction of the resistance wall structure, after forging the pre-formed blank, the forging was obtained with full filling and no folding defects, which successfully solved the problems existing in the original process. |
| Key words: 2A12 aluminum alloy folding defect pre-forging filling defect process optimization flash groove |
