Journal of Jilin University(Engineering and Technology Edition) ›› 2020, Vol. 50 ›› Issue (1): 84-90.doi: 10.13229/j.cnki.jdxbgxb20181219

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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

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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

CLC Number: 

  • TG316

Fig.1

"

Fig.2

Pre?forging shape design"

Fig.3

Cross?sectional view of three regions and regions of pre?forging"

Fig.4

Shape design of pre?forging height"

Table 1

Design project and regression analysis"

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

Fig.5

"

Table 2

Design project and regression analysis"

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

Fig.6

Numerical simulation of optimized pre?forging"

Fig.7

Measurement of forging"

Fig.8

Error distribution on loading platform and hook lock platform"

Fig.9

Error distribution on S face of knuckle"

Fig.10

Integral error distribution diagram"

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