铝合金汽车支架热锻缺陷分析及模具优化  

Analysis on hot forging defects of aluminum alloy automobile brackets and mould optimization

作　　者：吕弘毅[1] 龚红英[1] 缪军[1] 张杰[1] 

机构地区：[1]上海工程技术大学材料工程学院

出　　处：《锻压技术》2018年第1期117-123,共7页Forging & Stamping Technology

基　　金：2017年上海市研究生课程建设项目(A1-8944-17-0303);“基于材料科学与工程一级学科的研究生课程建设”校企合作项目(157CL-027;177CL-001)

摘　　要：为消除铝合金汽车发动机支架在热锻过程中所产生的折叠、充不满、起皮、表层剥离等各种缺陷,基于Deform-3D对6061铝合金汽车支架热锻成形过程进行了有限元模拟,发现缺陷产生的原因为预锻成形过程中金属流线紊乱、金属流动速度不均以及拐角处有多股金属汇流.针对缺陷产生的原因,提出了3种模具优化方案并分别进行模拟,对比分析了3种方案的锻造缺陷、金属充型效果和锻造载荷.结果表明,方案2和方案3成形结果良好,但相比方案2而言,方案3不需要改变预锻模具,故减少了加工成本且方案3的锻造载荷比方案2小1970 kN.所以,确认方案3为最优方案,并在压力机上进行小批量的生产验证,其生产结果与模拟结果相一致.In order to eliminate defects of folding,insufficient filling,peeling,skin peel off produced in the hot forging process of alumi-num alloy automobile engine brackets,the hot forging process of aluminum alloy 6061 for automobile brackets was numerically simulated by Deform-3D,and the reasons of defects were disturbances of metal flow lines,unsteady metal flow rates and multiple metal confluence at corners during the pre-forging process. According to the above reasons of defects,three kinds of molud optimization schemes were pro-posed and simulated separately,and the forging defects, metal filling effect and forging load were compared. The results show that the forming results of scheme 2 and scheme 3 are both good. However,compared with scheme 2,scheme 3 does not need to change the pre-forging mould to reduce the processing cost,and the forging load of scheme 3 is 1970 kN less than that of scheme 2. Therefore,scheme 3 is regarded as the best. Furthermore,the small batch production was produced on the press,and the production results and simulation results were consistent.

关 键 词：6061铝合金 汽车发动机支架 热锻缺陷 模具优化 DEFORM-3D 

分 类 号：TG319[金属学及工艺—金属压力加工]