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中南大学学报(自然科学版)

Journal of Central South University

第46卷    第3期    总第247期    2015年3月

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文章编号:1672-7207(2015)03-0804-08
基于类等势场法和模型的锻件预制坯设计
夏玉峰,陈邦华,杜婉婉,杨显红

(重庆大学 材料科学与工程学院,重庆,400044)

摘 要: 利用塑性变形过程中金属的流动规律与静电场等势线分布类似这一特性,提出一种预制坯设计的新方法—类等势场法,并采用此方法对某齿轮锻件进行预成形设计。利用ANSYS软件得出预制坯形状,以此形状为局部变量,以压机速度、摩擦因数、温度为全局变量,以成形载荷、填充率、晶粒尺寸为优化目标,利用有限元软件DEFORM-3D进行数值模拟,并采用Matlab软件中的MBC(model-based calibration)工具箱对其进行数学建模及优化,最后在预锻工艺参数不变的条件下,得到终锻的最佳工艺参数组合是等势线ξ为0.205 V时的预制坯形状及压机速度为56 mm/s、摩擦因数为0.2、温度为1 000 ℃。生产实践表明:该方法设计的齿轮与传统方法相比,终锻成形载荷下降40%,材料利用率提高56.7%,而且组织得到细化。

 

关键字: 齿轮锻件;等势场;预成形设计;优化;数值模拟

Pre-forming design in forging process based on equipotential field and model
XIA Yufeng, CHEN Banghua, DU Wanwan, YANG Xianhong

College of Material Science and Engineering, Chongqing University, Chongqing 400044, China

Abstract:According to the similarity between the metal flow law and the equipotential line of the electrostatic field, a new method for the pre-forming design in forging process was proposed as equi-potential field method and adopted for the per-forming design of gear forging. The preformed shapes were obtained by ANSYS software and chosen as a local variable, while speed of pressing machine, friction coefficient, temperature were chosen as the global variables, and forming load, filling ratio and grain size were chosen as optimization goals. DEFORM-3D software was used to simulate the forging process, model-based calibration(MBC) toolbox in Matlab software was used to build mathematics model, and finally, under the condition of pre-forging process parameters unchanged,the performed shape ξ of 0.205 V, the speed of pressing machine of 20 mm/s, the friction coefficient of 0.1 and the temperature of 600 ℃ were combined as the best parameters of finish forging. The production practice shows that the design of the gear compared with traditional methods reduces the forming load of finish forging by 40%, increases the utilization rate of material by 56.7%, and refines the microstructure.

 

Key words: gear forging; equipotential field; pre-forming design; optimization; numerical simulation

中南大学学报(自然科学版)
  ISSN 1672-7207
CN 43-1426/N
ZDXZAC
中南大学学报(英文版)
  ISSN 2095-2899
CN 43-1516/TB
JCSTFT
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