锻铝控制臂失效分析  

Failure analysis on forged aluminum control arm

作　　者：袁超 李卫红 马秋 李莉 Yuan Chao;Li Weihong;Ma Qiu;Li Li(Geely Automobile Research Institute(Ningbo)Co.,Ltd.,Ningbo 315336,China)

机构地区：[1]吉利汽车研究院(宁波)有限公司,浙江宁波315336

出　　处：《锻压技术》2021年第6期72-76,132,共6页Forging & Stamping Technology

摘　　要：某车型采用锻造铝合金控制臂,控制臂在下线路试动检过程中发生断裂。利用直读光谱分析仪、电子万能试验机、金相显微镜等设备和CAE模拟分析软件,对材料的理化性能和零件的成形过程进行分析。结果表明:材料的化学成分和力学性能均满足相关技术要求;零件金相组织无热处理过烧现象,但零件内部存在明显的锻造缺陷;锻造过程中由于弯曲工序定位不准确,产生折叠缺陷,锻造折叠缺陷最终导致本次控制臂断裂失效;通过在锻造弯曲工序中增加定位挡板和调节螺栓的方式,将预弯坯料偏离定位点的间距控制在5 mm以内,可以有效地避免锻造折叠缺陷的产生;在零件质检工序对所有零件进行表面荧光渗透探伤,可以防止问题零件的流出。Forged aluminum control arm was used on a certain kind of vehicle and fractured during offline road test procedure, and the physical and chemical performances of material and the forming process of part were analyzed by optical emission spectrometer, electronic universal testing machines, metallographic microscope and other equipments, as well as simulation analysis software CAE. The results show that the chemical compositions and tensile properties of material meet the related technical requirements. The metallographic structure of part has no heat treatment overburning phenomenon. But there are obvious forging defects inside the part. In the forging process, due to the inaccurate positioning of bending process, the folding defects are generated resulting in the fracture and failure for the control arm. Furthermore, by adding positioning baffles and adjusting bolts in the bending process of forging to control the spacing between pre-bending blank and positioning point within 5 mm, the generation of forging defects of forintg is effectively avoided, and the outflow of defective parts can be prevented by surface fluorescence permeation detection of all parts in the quality inspection process of part.

关 键 词：锻铝控制臂 失效 力学性能 断裂 折叠缺陷 

分 类 号：TG316[金属学及工艺—金属压力加工]