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

Previous Articles     Next Articles

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

RICH HTML

 3   

PDF (PC)

117

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"

1 陈玉清, 李林杰, 王广欣,等 . 新型锻造钩舌复杂曲面误差分析与调整方法［J］. 大连交通大学学报, 2013, 34(2):83-86.
Chen Yu-qing , Li Lin-jie , Wang Guang-xin , et al . Error analysis and method of adjusting complex curved surface of new forged coupler knuckle[J]. Journal of Dalian Jiaotong University, 2013, 34(2):83-86.
2 申恩强, 樊自田, 龙威,等 . 车钩钩舌的铸造工艺模拟与优化［J］. 铸造, 2011, 60(8):765-768.
Shen En-qiang , Fan Zi-tian , Long Wei , et al . Simulation and optimization of casting process for coupler knuckle[J]. Foundry, 2011, 60(8):765-768.
5 Wang Ning , Li Jian , Guan Zhi-jun , et al . Effect of processing parameters on strain distribution during near-isothermal canned forging for molybdenum powder sinter[J]. Journal of Materials Engineering, 2014, 43(23): 123-127.
6 赵新海,赵国群,王广春,等 . 锻造过程优化设计目标的研究[J].锻压装备与制造技术,2004, 39(1):48-52.
Zhao Xin-hai , Zhao Guo-qun , Wang Guang-chun , et al . Research on the establishment of objective function in forging optimization design[J]. China Metalforming Equipment & Manufacturing Technology, 2004, 39(1): 48-52.
7 Mirahmadi S J , Hamedi M , Ajami S . Investigating the effects of cross wedge rolling tool parameters on formability of Nimonic® 80A and Nimonic® 115 superalloys[J]. The International Journal of Advanced Manufacturing Technology, 2014, 74(5-8): 995-1004.
8 Quan G , Wang F , Liu Y , et al . Evaluation of varying ductile fracture criterion for 7075 aluminum alloy[J]. Transactions of Nonferrous Metals Society of China, 2013, 23(3): 749-755.
9 陈学文，王进，陈军，等 .热锻成形过程数值模拟与多目标设计优化技术研究［J］.塑性工程学报,2005(4):80-84.
Chen Xue-wen , Wang Jin , Chen Jun , et al . Research on multiple-objective design optimization and numerical simulation of hot forging process[J]. Journal of Plasticity Engineering,2005(4):80-84.
10 Stebunov Sergey , Vlasov Andrey , Biba Nikolai . Prediction of fracture in cold forging with modified Cockcroft-Latham criterion[J]. Procedia Manufacturing,2018(15):519-526.
[1] Wei-min ZHUANG,Hong-da SHI,Dong-xuan XIE,Guan-nan YANG. Thickness distribution of adhesive layer in dissimilar clinch⁃adhesive hybrid joint with steel and aluminum alloy [J]. Journal of Jilin University(Engineering and Technology Edition), 2020, 50(1): 100-106.
[2] Fang-wu MA,Hong-yu LIANG,Ying ZHAO,Meng YANG,Yong-feng PU. Multi⁃objective crashworthiness optimization design of concave triangles cell structure with negative Poisson′s ratio [J]. Journal of Jilin University(Engineering and Technology Edition), 2020, 50(1): 29-35.
[3] Qing-feng GUAN,Xin-wen YAO,Yang YANG,Ling-yan ZHANG,Di LIU,Chen LI,Peng LYU. Preparation and property of Cr alloying layer on TC4 after surface alloying induced by high current pulsed electron beam [J]. Journal of Jilin University(Engineering and Technology Edition), 2019, 49(6): 2002-2009.
[4] Zhou SHI,Shu-qing KOU. Performance analysis and lightweight design of 36MnVS4 fracture⁃splitting connecting rod [J]. Journal of Jilin University(Engineering and Technology Edition), 2019, 49(6): 1992-2001.
[5] Fu-chun JIA,Xian-jie MENG,Yu-long LEI. Optimal design of two degrees of freedom dynamic vibration absorber based on multi-objective genetic algorithm [J]. Journal of Jilin University(Engineering and Technology Edition), 2019, 49(6): 1969-1976.
[6] Xin LI,Yan-peng SUN,Dan WANG,Jun-xu CHEN,Zheng-wei GU,Hong XU. Finite element numerical simulation for automobile front floor forming [J]. Journal of Jilin University(Engineering and Technology Edition), 2019, 49(5): 1608-1614.
[7] Fang-wu MA,Lu HAN,Yang ZHOU,Shi-ying WANG,Yong-feng PU. Multi material optimal design of vehicle product using polylactic acid composites [J]. Journal of Jilin University(Engineering and Technology Edition), 2019, 49(5): 1385-1391.
[8] Xin LI,Dan WANG,Jun⁃xu CHEN,Yan⁃peng SUN,Zheng⁃wei GU,Hong XU. Numerical simulation for handbrake fixed plate forming [J]. Journal of Jilin University(Engineering and Technology Edition), 2019, 49(4): 1258-1265.
[9] Wen⁃quan LIU,Liang YING,Hai RONG,Ping HU. Forming limit prediction of high strength steel based on damage modified M⁃K model [J]. Journal of Jilin University(Engineering and Technology Edition), 2019, 49(4): 1266-1271.
[10] JIANG Qiu-yue,YANG Hai-feng,TAN Cai-wang. Strengthening properties of welded joints of 22MnB5 super high strength steel [J]. Journal of Jilin University(Engineering and Technology Edition), 2018, 48(6): 1806-1810.
[11] HU Zhi-qing, YAN Ting-xu, LI Hong-jie, LYU Zhen-hua, LIAO Wei, LIU Geng. Effect of cryogenic treatment on punch-shearing performance of aluminum alloy sheet [J]. Journal of Jilin University(Engineering and Technology Edition), 2018, 48(5): 1524-1530.
[12] QIU Xiao-ming, WANG Yin-xue, YAO Han-wei, FANG Xue-qing, XING Fei. Multi-objective optimization of resistance spot welding parameters for DP1180/DP590 using grey relational analysis based Taguchi [J]. 吉林大学学报(工学版), 2018, 48(4): 1147-1152.
[13] CHEN Jun-fu, GUAN Zhi-ping, YANG Chang-hai, NIU Xiao-ling, JIANG Zhen-tao, Song Yu-quan. Comparison of strain ranges and mechanical properties of metal rods under tension and torsion tests [J]. 吉林大学学报(工学版), 2018, 48(4): 1153-1160.
[14] GONG Ya-feng, SHEN Yang-fan, TAN Guo-jin, HAN Chun-peng, HE Yu-long. Unconfined compressive strength of fiber soil with different porosity [J]. 吉林大学学报(工学版), 2018, 48(3): 712-719.
[15] LIANG Xiao-bo, CAI Zhong-yi, GAO Peng-fei. Numerical simulation and experiment of cylindrical forming of sandwich composite panel [J]. 吉林大学学报(工学版), 2018, 48(3): 828-834.
Viewed
Full text


Abstract

Cited
  Shared   
  Discussed   
No Suggested Reading articles found!
Copyright © Journal of Jilin University(Engineering and Technology Edition), All Rights Reserved.
Tel: +86-431-85095297　Fax: +86-431-85094074　E-mail: xbgxb@jlu.edu.cn
Powered by Beijing Magtech Co. Ltd