【作者】 夏正宝；

【导师】 陈文琳；

【作者基本信息】 合肥工业大学 ， 材料加工工程， 2010， 硕士

【摘要】 汽车弯臂零件是汽车的保全件之一,在汽车运行中实现承载、导向功能,其工作运行环境比较复杂,使用的安全可靠性能要求也非常高。汽车弯臂零件传统的锻造工艺设计主要依靠经验进行试错设计,由于不能明确锻造过程中金属在模具中的流动情况,常造成坯料设计不合理导致锻件存在折纹、缺肉等缺陷,模具寿命低。随着计算机技术和数值计算方法的发展,以有限元法为代表的数值模拟技术被广泛的应用于分析金属塑性成形过程。本文根据热锻成形理论,以HF6700轻卡汽车弯臂为研究对象,主要研究内容如下：1.通过分析弯臂锻件结构特点,结合原有工艺提出了辊锻——摩擦压力机模锻的工艺,即下料→中频感应炉加热→辊锻制坯→630t摩擦压力机弯曲→1000t摩擦压力机终锻→热切边→热校正的成形工艺。2.利用有限元模拟软件,对弯臂锻件多道次锻造成形建立了三维热力耦合有限元模型,并进行了有限元模拟分析。通过模拟得到合理的制坯形状和尺寸,辊锻、预弯、终锻的金属流动分布等,为模具的设计和实际生产操作提供了依据和参考。3.基于Archard磨损模型,研究了终锻成形时模具预热温度T预热,摩擦因子m和模具初始硬度HRC对模具磨损量w的影响规律,并对终锻模具的模具寿命进行了预测。更多还原

【Abstract】 Automotive steering knuckle arm is one of the safety parts, which to achieve load and guidance functions in the car is running. Their work more complex operating environment, the use of security and reliability requirements can be very high. The traditional forging process design mainly rely on the experiences of trial and error design, the lack of a clear steering knuckle arm forging metal in the process of the flow in the mold, often caused by an unsuitable design billets, forgings there folding patterns, lack of meat and other defects, low die life. With the computer technology and numerical calculation methods development, as represented by the finite element method numerical simulation technique has been widely used in analysis of metal forming processes.In the paper, based on the hot forging forming theory, take HF6700 steering knuckle arm of light truck as the research object, the main research contents are as follows:1. By analyzing the structural characteristics of steering knuckle arm forging, combined with the original technique proposed roll forging-friction press forging process, that is, baiting→medium-frequency induction furnace heating→Roll forging billet (2 times)→630t friction screw press bending→1000t friction screw press for the final forging→hot side cut→hot correction.2. Using finite element simulation software, established a three-dimensional coupled thermo-mechanical model and taken the finite element simulation for multi-pass forging process of steering knuckle arm. Through simulation and optimization of the system blank of blank shape and size, obtain the metal flow distribution of roll forging, pre-bend, and finally forging, analysis of each pass of the strain field, stress field, velocity field and forming load and so on, for mold design and the actual manufacturing operations provides the basis and reference.3. Based on the Archard wear model, research the law of the final forging die when the preheating temperature Tpre, friction factor m and the initial die hardness of HRC on the influence of the amount of die wearing, and predicted die life for the last forging die.更多还原