基于CAE的汽车铝合金控制臂锻造成形工艺  

Forging process on automotive aluminum alloy control arm based on CAE

作　　者：周礼菊 孙如梦 高振伟 司大强 王雷刚[1] Zhou Liju;Sun Rumeng;Gao Zhenwei;Si Daqiang;Wang Leigang(School of Materials Science and Engineering,Jiangsu University,Zhenjiang 212013,China;Jiangsu Xingduan Intelligent Equipment Technology Co.,Ltd.,Liyang 213300,China)

机构地区：[1]江苏大学材料科学与工程学院,江苏镇江212013 [2]江苏兴锻智能装备科技有限公司,江苏溧阳213300

出　　处：《锻压技术》2024年第3期1-7,共7页Forging & Stamping Technology

基　　金：国家自然科学基金资助项目(51775249)。

摘　　要：以某汽车右上控制臂为研究对象,选用6082铝合金为锻造材料,分析了产品的结构特点及成形难点,确定了其成形工艺为两道次辊锻、两工位弯曲、预锻和终锻。根据锻模设计理论,采用Solidworks软件设计各道次模具,并通过Deform软件对6082铝合金控制臂成形过程进行模拟,从温度分布、等效应力应变以及金属流动等角度分析了各工序的成形情况。针对成形方案中变形程度最大的预锻工序,采用控制单一变量的方法,分析了坯料始锻温度及摩擦因数对预锻成形的影响。结果表明:预锻时,随着始锻温度的增加,平均等效应力减小,始锻温度在450~490℃时更合理;改善润滑,减小摩擦因数使得模具载荷降低,锻件的最大等效应变减小,有利于成形且提升模具寿命。最后,基于模拟结果结合实际生产进行了试验,得到了与模拟结果相吻合的成形锻件。For the upper right control arm of an automobile,taking 6082 aluminum alloy as the forging material,the structural characteristics and forming difficulties of product were analyzed,and its forming process was determined to be two-pass roll forging,two-station bending,pre-forging and final forging.Then,according to the design theory of forging die,each pass die was designed by software Solidworks,the forming process of 6082 aluminum alloy control arm was simulated by software Deform,and the forming situation of each process was analyzed from the perspective of temperature distribution,stress-strain and metal flow.Furthermore,for the pre-forging process with the largest deformation degree in the forming scheme,the influences of billet temperature and friction factor on the pre-forging forming were analyzed by controlling a single variable.The results show that during pre-forging,with the increasing of initial forging temperature,the average equivalent stress decreases,and the initial forging temperature is more reasonable at 450-490℃.Moreover,improved lubrication and reduced friction factors can reduce the die load and the maximum equivalent strain of forgings,and prolong the service life of die.Finally,based on the simulation results and combined with the actual production,the experiment shows that the formed forgings obtained is consistent with the simulation results.

关 键 词：6082铝合金 控制臂 模具设计 辊锻 弯曲 预锻 终锻 

分 类 号：TG316[金属学及工艺—金属压力加工]