基于成形过程的闭塞式冷锻工艺优化

针对闭塞式冷锻工艺复杂、单纯在某个成形阶段优化金属填充性和成形力无法使工艺参数达到最佳值的问题,提出了一种基于成形过程的冷锻工艺多目标优化方法.结合有限元模拟技术和正交试验方法,在闭塞式冷锻基本成形阶段使金属填充性达到最佳,实现金属填充性的优化,获得相应的工艺参数组;然后采用目标函数值拟合优化方法研究了飞边槽高度与凸模下压量之间的关系,通过控制飞边槽高度使成形力在最终填充阶段达到最小,实现了成形力的优化,在保证金属填充性最优的前提下获得了新的使成形力最小的优化工艺参数组,实现了金属填充性和成形力的分过程优化,优化得到的工艺参数组与物理实验数据一致.研究结果表明,所提出的方法充分考虑了闭塞式冷锻工艺的成形特点,能更简便、更准确、更合理地实现闭塞式冷锻工艺的参数优化.

Optimization of Block-Type Cold Forging Process Based on Forming Procedure

Due to the great complexity of the block-type cold forging process,it is difficult to obtain the best forging parameters by optimizing the metal filling ability and the forming force only at a process stage.In order to solve this problem,a multi-objective optimization method based on the forming process is put forward.In this method,the finite element simulation and the orthogonal test are combined to achieve the best metal filling ability at the basic forming stage.Thus,the metal filling ability is optimized and a set of relevant process parameters is obtained.Then,the fitting optimization method based on objective function values is employed to analyze the relationship between the flash slots height and the drop quantity of punch.Thus,the forming force is optimized through controlling the flash slots height to achieve the minimum forming force at the last filling stage,and a set of optimum process parameters that simultaneously ensures the best metal filling ability and the minimum forming force is determined.Through the above-mentioned statements,the metal filing ability and the forming force are optimized at different stages,and the optimized results accord well with the physical experimental ones.It is demonstrated that,as the proposed method fully considers the forming characteristics of the block-type cold forging,it helps to obtain more accurate and reasonable forging parameters with simplicity.