CN104636557A - Method for conducting analog simulation on crank die forging process through computer aided engineering (CAE) - Google Patents
Method for conducting analog simulation on crank die forging process through computer aided engineering (CAE) Download PDFInfo
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- CN104636557A CN104636557A CN201510070476.7A CN201510070476A CN104636557A CN 104636557 A CN104636557 A CN 104636557A CN 201510070476 A CN201510070476 A CN 201510070476A CN 104636557 A CN104636557 A CN 104636557A
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Abstract
The invention belongs to the technical field of metal plastic forming processes, and provides a method for conducting analog simulation on the crank die forging process through computer aided engineering (CAE). The method includes the steps of extracting the parting surface chamfer of a pre-forging die chamber, the length ratio factor of the pre-forging die chamber and a final-forging die chamber, the width ratio factor of the pre-forging die chamber and a final-forging die chamber and the height ratio factor of the pre-forging die chamber and a final-forging die chamber through orthogonal experiments, and establishing a factor level table; forging a CAE sample and an actual crank by drawing a crank model through CAD; conducting final-forging load testing, wherein the maximum forming load of the pre-forging die chamber is achieved when the partial surface chamfer is 8, the length ratio is 0.998, the width ratio is 0.98 and the height ratio is 1.12, and the maximum final forging forming load is achieved when the partial surface chamfer is 8, the length ratio is 0.998, the width ratio is 0.95 and the height ratio is 1.09. The finite element principle analysis method which has quite high representativeness, practicability and scientificity has the advantages that workloads are reduced, implementation is easy, the optimal conclusion is obtained, the forming load is greatly reduced, the forming defects are eliminated, and the die service life is prolonged.
Description
Technical field
The invention belongs to metal forming technology field, particularly a kind of method of computer-aided engineering CAE analog simulation bent axle contour forging technique.
Background technology
Bent axle, as the key components and parts of engine, is called the heart of engine.Bent axle, in operation process, needing the alterante stress of carry load all the time, in order to ensure automobile normal running, needing its bent axle to have the performances such as fabulous toughness, wearing quality and fatigue resistence intensity.Therefore, during in order to make crankshaft operation, each performance is all up to standard, has strict specification to the selection, forming technology, transient equilibrium etc. of bent axle.
As typical complex die forging, easily produce in crankshaft forging forming process fold, be not fully filled, the defect such as crackle.Nowadays, the performances such as stable dynamic property, the economy of fuel oil and heavy duty have become the important indicator passing judgment on car mass quality, so propose more harsh requirement to aspect performances such as die forging crankshaft strength and precision.Therefore, for improving bent axle various aspects of performance, extremely crucial effect is served to the improvement of die forging forming process.
At present, combined by Finite Element Principle and die forging forming process, use Computer Aided Design of Models cad technique and computer-aided engineering CAE emulation technology, numerical simulation is carried out to Die Forging Formation Course for Crankshaft, to realize the optimization of forming technology, finally reach reduction shaping load, eliminate forming defects, improve the objects such as die life, but still there are the following problems: (1) needs to select a large amount of numerical value to carry out Finite Element Principle analysis, workload is large, is difficult to implement; (2) although be optimized, degree of optimization is limited, reduces shaping load, eliminates forming defects, to improve the degree of die life little, do not draw optimum solution, still exist easily produce fold, be not fully filled, the problem such as crackle.
Therefore, a kind of Finite Element Principle analytical approach with very strong representativeness, practicality and science is badly in need of in metal forming technology field, reduce workload, implement easily, draw optimum conclusion, the method reducing shaping load greatly, eliminate forming defects, improve the computer-aided engineering analog simulation bent axle contour forging technique of die life.
Summary of the invention
The invention provides a kind of method of computer-aided engineering CAE analog simulation bent axle contour forging technique, technical scheme is as follows:
The method of computer-aided engineering CAE analog simulation bent axle contour forging technique, comprises the steps:
Step one, adopts orthogonal experimental method, extracts the length scale factor of blocker die joint fillet, blocker and finish impression, forms 4 factors, and then set up factor level table;
Step 2, according to factor level table, by CAD Software on Drawing crank-resolved model;
Step 3, the crank-resolved model sample according to 16 groups of orthogonal scheme carries out CAE analogue simulation;
Step 4, by the emulation experiment completing 16 suite axle die forgings, extracts blocking, finish-forging load data;
Step 5, according to blocking, the finish-forging load data of step 4, draw: when die joint fillet gets 8, length ratio gets 0.998, and width ratio gets 0.98, and blocker shaping load when height ratio gets 1.12 is maximum, blocker design is ideal, and height ratio is the most responsive on the impact of blocking bent axle shaping load, be secondly length ratio, and width ratio and die joint fillet affects less comparatively speaking; When die joint fillet gets 8, length ratio gets 0.998, width ratio gets 0.95, finish impression shaping load when height ratio gets 1.09 is maximum, finish impression design is ideal, and width ratio is the most responsive on the impact of bent axle finish-forging shaping load, is secondly length ratio, and die joint fillet and height ratio affect minimum on bent axle finish-forging shaping load.
Preferably, in the method for computer-aided engineering CAE analog simulation bent axle contour forging technique, the factor level table formed in step one is
orthogonal test table, represent and need to do 16 groups of tests, containing 4 factors, the number of levels of each factor is 4, and material elements water-glass is:
Preferably, in the method for computer-aided engineering CAE analog simulation bent axle contour forging technique, the forging CAE sample in step 3 and the production process of actual crank are followed successively by: blanking, Frequency Induction Heating, blocking and finish-forging technique, hot trimming and thermal recalibration technique, controlled process for cooling, detection, process for machining.
Preferably, in the method for computer-aided engineering CAE analog simulation bent axle contour forging technique, the finish-forging load test Plotting data of step 4 is become form, specific as follows:
Preferably, in the method for computer-aided engineering CAE analog simulation bent axle contour forging technique, the blocking in step 5, finish-forging load test data and stress-strain curve are analyzed, and then draw the conclusion of step 5, make a concrete analysis of as follows:
The range analysis table of bent axle blocking shaping after load is as follows, and the average in table represents that each factor is when level values of fetching water is constant, the mean value of the four groups of end values obtained;
Analyze based on above-mentioned orthogonal experiment data, obtain level of optimization die joint fillet, length ratio, width ratio, height ratio sequence number be 2,2, Isosorbide-5-Nitrae; Data are known thus, and die joint fillet gets 8, and length ratio gets 0.998, and width ratio gets 0.98, and when height ratio gets 1.12, the blocker design of the program is ideal; From extreme difference, height ratio is the most responsive on the impact of bent axle shaping load, be secondly length ratio, and width ratio and die joint fillet affects less comparatively speaking;
Blocking is shaped and carries out variance data analysis, draw following data:
As can be seen from above-mentioned variance analysis: these four factors of die joint fillet, length ratio, width ratio, height ratio are to the size difference to some extent of the influence degree that bent axle blocking is shaped, and size is followed successively by: height ratio > length ratio > width ratio > die joint fillet;
It is be based upon on the basis of blocking shaping that the finish-forging of bent axle is shaped, Integral die-forged is carried out with after the forging being met designing requirement to blank after blocking, carry out finish-forging shaping, the range analysis table of bent axle finish-forging shaping after load as shown in Table 5, average in table represents that each factor is when getting certain level value and being constant, the mean value of the four groups of end values obtained;
Based on the data analysis of above-mentioned finish-forging extreme difference, obtain level of optimization die joint fillet, length ratio, width ratio, height ratio sequence number be 2,2,4,3, the factor level table corresponding to table one draws: die joint fillet gets 8, length ratio gets 0.998, width ratio gets 0.95, and when height ratio gets 1.09, the finish impression design of the program is ideal;
Finish-forging is shaped and carries out variance data analysis, draw following data:
From variance data analysis, these four factors of die joint fillet, length ratio, width ratio, height ratio are to the size difference to some extent of the influence degree that bent axle finish-forging is shaped, and size is followed successively by: width ratio > length ratio > die joint fillet > height ratio.
Beneficial effect of the present invention:
1, the present invention is by adopting orthogonal experimental method, only need to do 16 tests just can length scale factor 4 factors of blocker die joint fillet, blocker and finish impression more all sidedly on the impact of bent axle die-forging forming, instead of comprehensive test method need carry out 4
4=256 groups of tests, have very strong representativeness, practicality and science, reduce workload large, reduce work difficulty, easy to implement.
2, by cross finish-forging load test data and stress-strain curve is analyzed, shown that die joint fillet gets 8, length ratio gets 0.998, and width ratio gets 0.95, height ratio gets the optimum solution of 1.09, reduces shaping load greatly, eliminates forming defects, improves die life.
3, the mode by drawing form and curve is carried out intuitively data, the analysis of science, makes result more have cogency.
4. analog simulation result is closely with test production result, is formed with comparatively restricted publication of international news and commentary entitled is worth optimization crankshaft forging.
Accompanying drawing explanation
The present invention is described in detail below in conjunction with the drawings and specific embodiments:
Fig. 1 is the crank-resolved model structural representation of the present invention by CAD Software on Drawing.
Fig. 2 is the crank-resolved model structural representation that the present invention forges according to CAE.
Fig. 3 is that the structure of taking away that the present invention produces according to physical size is intended to.
Embodiment
The measure realized to make the technology of the present invention, creation characteristic, reaching object and effect is easy to understand, below in conjunction with concrete diagram, setting forth the present invention further.
The invention provides a kind of method of computer-aided engineering CAE analog simulation bent axle contour forging technique, comprise the steps:
Step one, adopts orthogonal experimental method, extracts the length scale factor of blocker die joint fillet, blocker and finish impression, forms 4 factors, and then set up factor level table, specifically as shown in Table 1:
Table one
Step 2, according to factor level table, by CAD Software on Drawing crank-resolved model as shown in Figure 1;
Step 3, according to the CAE analogue simulation that the crank-resolved model sample of 16 groups of orthogonal scheme carries out as shown in Figure 2;
Forging CAE sample and the production process of actual crank are followed successively by: blanking, Frequency Induction Heating, blocking and finish-forging technique, hot trimming and thermal recalibration technique, controlled process for cooling, detection, process for machining;
Step 4, by the emulation experiment completing 16 suite axle die forgings, extracts blocking, finish-forging load data, concrete data as shown in Table 2:
Table two
Step 5, according to blocking, the finish-forging load data of step 4, draw: when die joint fillet gets 8, length ratio gets 0.998, and width ratio gets 0.98, and blocker shaping load when height ratio gets 1.12 is maximum, blocker design is ideal, and height ratio is the most responsive on the impact of blocking bent axle shaping load, be secondly length ratio, and width ratio and die joint fillet affects less comparatively speaking; When die joint fillet gets 8, length ratio gets 0.998, width ratio gets 0.95, finish impression shaping load when height ratio gets 1.09 is maximum, finish impression design is ideal, and width ratio is the most responsive on the impact of bent axle finish-forging shaping load, is secondly length ratio, and die joint fillet and height ratio affect minimum on bent axle finish-forging shaping load, make a concrete analysis of as follows:
As shown in Table 3, the average in table represents that each factor is when level values of fetching water is constant to the range analysis table of bent axle blocking shaping after load, the mean value of the four groups of end values obtained;
The range analysis of table three blocking
Analyze based on above-mentioned orthogonal experiment data, obtain level of optimization die joint fillet, length ratio, width ratio, height ratio sequence number be 2,2, Isosorbide-5-Nitrae; Data contrast factor level table is known thus, and die joint fillet gets 8, and length ratio gets 0.998, and width ratio gets 0.98, and when height ratio gets 1.12, the blocker design of the program is ideal; From extreme difference, height ratio is the most responsive on the impact of bent axle shaping load, be secondly length ratio, and width ratio and die joint fillet affects less comparatively speaking;
Blocking is shaped and carries out variance data analysis, draw data as shown in Table 4:
The variance analysis of table four blocking
As can be seen from above-mentioned variance analysis: these four factors of die joint fillet, length ratio, width ratio, height ratio are to the size difference to some extent of the influence degree that bent axle blocking is shaped, and size is followed successively by: height ratio > length ratio > width ratio > die joint fillet;
It is be based upon on the basis of blocking shaping that the finish-forging of bent axle is shaped, Integral die-forged is carried out with after the forging being met designing requirement to blank after blocking, carry out finish-forging shaping, the range analysis table of bent axle finish-forging shaping after load as shown in Table 5, average in table represents that each factor is when getting certain level value and being constant, the mean value of the four groups of end values obtained;
The range analysis of table five finish-forging
Based on the data analysis of above-mentioned finish-forging extreme difference, obtain level of optimization die joint fillet, length ratio, width ratio, height ratio sequence number be 2,2,4,3, contrast factor level table draws: die joint fillet gets 8, length ratio gets 0.998, width ratio gets 0.95, and when height ratio gets 1.09, the finish impression design of the program is ideal;
Finish-forging is shaped and carries out variance data analysis, draw data as shown in Table 6:
The variance analysis of table six finish-forging
From variance data analysis, these four factors of die joint fillet, length ratio, width ratio, height ratio are to the size difference to some extent of the influence degree that bent axle finish-forging is shaped, and size is followed successively by: width ratio > length ratio > die joint fillet > height ratio.
Optimize the blocker of bent axle and the structure of finish impression by orthogonal scheme, with actual crank as shown in Figure 3, production result tested to bent axle analog simulation result as shown in Figure 2 and is analyzed:
Under bent axle finish-forging is shaped the prerequisite that is all full of, bent axle simulation result and test production result are contrasted in size and in load, as shown in Table 7:
Table seven foot cun and load parameter contrast
As table seven is known, except the overlap error of portion is slightly larger, other parameters all control below 2% substantially, and maximum shaping load is also comparatively close, have good guiding value for actual production; In a word, analog simulation result and test production result still closely, are formed with comparatively restricted publication of international news and commentary entitled to optimization crankshaft forging and are worth.
The present invention is by adopting orthogonal experimental method, only need to do 16 tests just can length scale factor 4 factors of blocker die joint fillet, blocker and finish impression more all sidedly on the impact of bent axle die-forging forming, instead of comprehensive test method need carry out 4
4=256 groups of tests, have very strong representativeness, practicality and science, reduce workload large, reduce work difficulty, easy to implement.
The present invention is by cross finish-forging load test data and stress-strain curve is analyzed, shown that die joint fillet gets 8, length ratio gets 0.998, and width ratio gets 0.95, height ratio gets the optimum solution of 1.09, reduces shaping load greatly, eliminates forming defects, improves die life.
The present invention is carried out intuitively data by the mode of drawing form and curve, the analysis of science, makes result more have cogency.
Analog simulation result of the present invention is closely with test production result, is formed with comparatively restricted publication of international news and commentary entitled is worth optimization crankshaft forging.
More than show and describe ultimate principle of the present invention, principal character and advantage of the present invention.The technician of the industry should understand; the present invention is not restricted to the described embodiments; what describe in above-described embodiment and instructions just illustrates principle of the present invention; the present invention also has various changes and modifications without departing from the spirit and scope of the present invention, and these changes and improvements all fall in the claimed scope of the invention.Application claims protection domain is defined by appending claims and equivalent thereof.
Claims (5)
1. the method for computer-aided engineering CAE analog simulation bent axle contour forging technique, comprises the steps:
Step one, adopts orthogonal experimental method, extracts the length scale factor of blocker die joint fillet, blocker and finish impression, forms 4 factors, and then set up factor level table;
Step 2, according to factor level table, by CAD Software on Drawing crank-resolved model;
Step 3, the crank-resolved model sample according to 16 groups of orthogonal scheme carries out CAE analogue simulation;
Step 4, by the emulation experiment completing 16 suite axle die forgings, extracts blocking, finish-forging load data;
Step 5, according to blocking, the finish-forging load data of step 4, draw: when die joint fillet gets 8, length ratio gets 0.998, and width ratio gets 0.98, and blocker shaping load when height ratio gets 1.12 is maximum, blocker design is ideal, and height ratio is the most responsive on the impact of blocking bent axle shaping load, be secondly length ratio, and width ratio and die joint fillet affects less comparatively speaking; When die joint fillet gets 8, length ratio gets 0.998, width ratio gets 0.95, finish impression shaping load when height ratio gets 1.09 is maximum, finish impression design is ideal, and width ratio is the most responsive on the impact of bent axle finish-forging shaping load, is secondly length ratio, and die joint fillet and height ratio affect minimum on bent axle finish-forging shaping load.
2. the method for computer-aided engineering CAE analog simulation bent axle contour forging technique according to claim 1, is characterized in that, the factor level table formed in described step one is
orthogonal test table, represent and need to do 16 groups of tests, containing 4 factors, the number of levels of each factor is 4, and material elements water-glass is:
。
3. the method for computer-aided engineering CAE analog simulation bent axle contour forging technique according to claim 1, it is characterized in that, the forging CAE sample in described step 3 and the production process of actual crank are followed successively by: blanking, Frequency Induction Heating, blocking and finish-forging technique, hot trimming and thermal recalibration technique, controlled process for cooling, detection, process for machining.
4. the method for computer-aided engineering CAE analog simulation bent axle contour forging technique according to claim 2, is characterized in that, the finish-forging load test Plotting data of described step 4 is become form, shown in specific as follows:
。
5. the method for computer-aided engineering CAE analog simulation bent axle contour forging technique according to claim 4, it is characterized in that, blocking in described step 5, finish-forging load test data and stress-strain curve are analyzed, and then draw the conclusion of step 5, make a concrete analysis of as follows:
The range analysis table of bent axle blocking shaping after load is as follows, and the average in table represents that each factor is when level values of fetching water is constant, the mean value of the four groups of end values obtained;
Analyze based on above-mentioned orthogonal experiment data, obtain level of optimization die joint fillet, length ratio, width ratio, height ratio sequence number be 2,2, Isosorbide-5-Nitrae; Data are known thus, and die joint fillet gets 8, and length ratio gets 0.998, and width ratio gets 0.98, and when height ratio gets 1.12, the blocker design of the program is ideal; From extreme difference, height ratio is the most responsive on the impact of bent axle shaping load, be secondly length ratio, and width ratio and die joint fillet affects less comparatively speaking;
Blocking is shaped and carries out variance data analysis, draw the data as table four:
As can be seen from above-mentioned variance analysis: these four factors of die joint fillet, length ratio, width ratio, height ratio are to the size difference to some extent of the influence degree that bent axle blocking is shaped, and size is followed successively by: height ratio > length ratio > width ratio > die joint fillet;
It is be based upon on the basis of blocking shaping that the finish-forging of bent axle is shaped, Integral die-forged is carried out with after the forging being met designing requirement to blank after blocking, carry out finish-forging shaping, the range analysis table of bent axle finish-forging shaping after load as shown in Table 5, average in table represents that each factor is when getting certain level value and being constant, the mean value of the four groups of end values obtained;
Based on the data analysis of above-mentioned finish-forging extreme difference, obtain level of optimization die joint fillet, length ratio, width ratio, height ratio sequence number be 2,2,4,3, the factor level table corresponding to table one draws: die joint fillet gets 8, length ratio gets 0.998, width ratio gets 0.95, and when height ratio gets 1.09, the finish impression design of the program is ideal;
Finish-forging is shaped and carries out variance data analysis, draw following data:
From variance data analysis, these four factors of die joint fillet, length ratio, width ratio, height ratio are to the size difference to some extent of the influence degree that bent axle finish-forging is shaped, and size is followed successively by: width ratio > length ratio > die joint fillet > height ratio.
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| CN201510070476.7A CN104636557A (en) | 2015-02-10 | 2015-02-10 | Method for conducting analog simulation on crank die forging process through computer aided engineering (CAE) |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107391779A (en) * | 2016-05-17 | 2017-11-24 | 中国科学院金属研究所 | A kind of blank shape design method of die forging crankshaft of diesel engine |
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- 2015-02-10 CN CN201510070476.7A patent/CN104636557A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107391779A (en) * | 2016-05-17 | 2017-11-24 | 中国科学院金属研究所 | A kind of blank shape design method of die forging crankshaft of diesel engine |
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