基于有限元模拟的机车齿轮锻件的毛坯形状优化  

Optimization of locomotive gear forging blank shape based on FE simulation

作　　者：储文平 张琳[1] 王雷刚[1] 

机构地区：[1]江苏大学材料科学与工程学院,江苏镇江212013

出　　处：《锻压技术》2014年第5期13-18,共6页Forging & Stamping Technology

基　　金：江苏省研究生企业工作站项目

摘　　要：针对机车齿轮锻件在成形过程中容易出现轮毂和轮辋充填不满、成形力较大和模具寿命短的问题,根据坯料在不同自由空间下不同填充情况,提出了上凹形坯料的新方案。利用有限元软件Deform-3D建立机车齿轮锻件热锻有限元模型,并模拟其成形过程。以成形载荷作为目标函数,采用黄金分割法,对镦粗毛坯直径进行优化设计,使锻件在成形饱满的前提下,将成形载荷降低了31.76%,提高了模具寿命。实际生产与有限元模拟具有较好的一致性,锻件形状满足设计要求,无缺料、折痕等缺陷。During forming process of locomotive gear forgings, unfilled zones easily appear in the hub and the rim, the forming force is very large, and the die life is short. To solve these problems, a new scheme of up concave blank according to different filling states of blank under different free spaces was put forward. Finite element model of gear blank forging was established by using the finite element software Deform -3D, and the forming process was simulated. Taking the forming load as objective function, the blank diameter was opti- mized by using the golden section method, which lead that forming load reduced by 31.76% when the forging was full filled, and thereby die life was improved. A good agreement was found between the simulation and experimental resuhs. The shape of forging parts meets the design requirements without unfilled zones and folding defects.

关 键 词：机车齿轮 毛坯形状 黄金分割法 有限元模拟 

分 类 号：TG316[金属学及工艺—金属压力加工]