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对一种车用曲轴的弯曲镦锻成形工艺难点和解决措施进行了研究。采用有限元模拟方法,直观地再现了曲拐镦挤成形过程中的金属流动情况和容易出现的成形缺陷,研究了飞边厚度和过渡圆角大小对曲拐成形质量的影响,优化出飞边预留厚度为8 mm、曲臂顶部过渡圆角为R5 mm、主轴颈部过渡圆角为R3 mm时,能够获得无缺陷的曲拐。以单拐曲轴为研究对象,开展了曲轴弯曲镦锻成形的工艺试验,验证了模拟结果的准确性,最终制备出的单拐曲轴充型饱满,飞边合理,没有出现塌角、折叠等缺陷,质量完全能够满足技术要求。
The difficulty and solution to the bending upsetting for a kind of automobile crankshaft were studied. The finite element simulation method was used to directly visualize the metal flow and forming flaws during the upsetting extrusion process of bellcranks. The influence of the thickness and the transition fillet on the forming quality was studied, and the flashover With a reserved thickness of 8 mm, a transition radius of R5 mm at the top of the arm and a transition radius of R3 mm at the neck of the spindle, a flawless bell crank is obtained. The single crankshaft crankshaft is taken as the research object to test the crankshaft bending upsetting process. The accuracy of the simulation results is verified. Finally, the single crankshaft crankshaft is fully filled, the burrs are reasonable, and there are no defects such as collapse and folding , The quality can fully meet the technical requirements.