吉林大学学报(工学版) ›› 2020, Vol. 50 ›› Issue (1): 84-90.doi: 10.13229/j.cnki.jdxbgxb20181219

• 材料科学与工程 • 上一篇    下一篇

复杂钩舌锻件近净成形的预锻形状优化设计

蔡中义1,2(),孟凡响2,陈庆敏1(),赵轩2   

  1. 1. 吉林大学 辊锻工艺研究所,长春 130022
    2. 吉林大学 材料科学与工程学院 长春 130022
  • 收稿日期:2018-12-10 出版日期:2020-01-01 发布日期:2020-02-06
  • 通讯作者: 陈庆敏 E-mail:caizy@jlu.edu.cn;chenqm@jlu.edu.cn
  • 作者简介:蔡中义(1963-),男,教授,博士生导师.研究方向:材料柔性成形,有限元理论.E-mail:caizy@jlu.edu.cn
  • 基金资助:
    国家自然科学基金项目(51575231)

Preform optimization for near-net-shape forming process of complex knuckle forging

Zhong-yi CAI1,2(),Fan-xiang MENG2,Qing-min CHEN1(),Xuan ZHAO2   

  1. 1. Rolling Forging Institute, Jilin University, Changchun 130022, China
    2. College of Materials Science and Engineering, Jilin University, Changchun 130022, China
  • Received:2018-12-10 Online:2020-01-01 Published:2020-02-06
  • Contact: Qing-min CHEN E-mail:caizy@jlu.edu.cn;chenqm@jlu.edu.cn

摘要:

提出了基于闭式模锻的铁路钩舌锻件的近净成形工艺方案,针对近净成形中的预锻成形件设计这一关键技术进行了研究。通过对终锻成形阶段金属流动特点的分析,设计了预锻成形工艺。将多重响应面法与数值模拟相结合,以锻件填充完整、锻件变形均匀性最好以及材料的损伤最小为目标函数对预锻成形件的形状进行了多目标优化,并通过成形试验验证了优化设计的结果。测量与分析结果表明,本文方法可获得优化的预锻件形状,基于本文设计出的预锻件,可得到无成形缺陷且精度好的终锻成形件,实现了钩舌锻件的近净成形。

关键词: 材料合成与加工工艺, 钩舌锻件, 近净成形, 预成形, 多目标优化, 响应面法

Abstract:

A near net forming process scheme for railway knuckle forgings based on closed die forging is proposed, and the key technical problems in the design of pre-forged parts in near net forming are studied. The pre-forming process was designed by analyzing the metal flow characteristics in the final forging stage. Combining the multiple response surface method with the numerical simulation, the shape of the pre-forged formed part was optimized by the muli-objective function, in which the objectives include the complete filling and the best deformation uniformity of the forging part and the minimum damage of the material. The optimization was verified by the forming test. The measurement and analysis results show that the proposed method can obtain the shape of the optimized pre-forging. Based on the designed pre-forging, the final forged part without forming defects and high precision can be obtained, which can realize the near net forming of the knuckle forging.

Key words: materials synthesis and processing technology, railway knuckle forging, near net forming, pre-forming, multi-objective optimization, response surface method

中图分类号: 

  • TG316

图1

钩舌近净成形工艺"

图2

预锻件形状设计"

图3

预锻件的3个区域及各区域横截面图"

图4

预锻件高度形状设计"

表1

试验方案及回归分析"

因素 -2 -1 0 1 2 Prob>F
R 2 0.9731 Prob>F of model <0.0001
a 0.64 0.66 0.68 0.70 0.72 0.0390
d 0.40 0.45 0.50 0.55 0.60 0.0007

图5

充填能力响应曲面及响应优化图"

表2

试验方案及回归分析"

Exp.no. -2 -1 0 1 2 Prob>F
b 12.00 14.50 17.00 19.50 22.00 0.002 6
c 70.00 72.50 75.00 77.50 80.00 <0.000 1
d 0.53 0.542 5 0.555 0.567 5 0.58 <0.000 1
ANOVA f 1 f 2 minf
R 2 0.935 8 0.946 2 0.986 4
Prob>F <0.000 1 <0.000 1 <0.000 1

图6

优化预锻件的数值模拟"

图7

锻件的测量"

图8

承载台及钩锁承台误差分布"

图9

钩舌S面误差分布"

图10

整体误差分布"

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