外文翻译--复杂弯轴压力机模锻复合锻造工艺

Complicated Curved The Stalk Pressure Machine Mold Duan Compound Forge CraftSummaryAim at the technique characteristics of many problems and that type of Duan piece oneselfs of the light sedan complicated and curved stalk Duan piece existing production craft, this text puts forward Gun Duan-rub the pressure machine mold Duan compound craft project, introduce concerning the semi-finished product of Gun Duan, bent semi-finished product, curve back to play, curve a work preface of reasonable arrangement etc. technological design important point and the reasonable structure and design of the molding tool.Be investigated enunciation by actual production:This craft project forerunner reasonable, the production line stabilize credibility, the economic efficiency shows Zhao.The technological design method in this text as to its it complicated curved stalk Duan the piece contain universal reference meaningKeyword:Complicated curved stalk Duan piece;Compound forging craft;Light sedanA, forewordComplicated and curved stalk Duan piece of the best take shape a method have been the problem that forges profession to concentrate on a research, a little bit ex- year of our country light sedan production amount not big, dont form scale management, the past light sedan is complicated curved stalk Duan the production of the piece mainly with mold Duan of traditional hammer the craft carry on small batch quantity production, the factory house for having even adopts free Duan-foetus mold Duan craft, needing several fire times then can Duan become.In recent years, our country the light sedan production quickly develops and produces a batch quantity more and more greatly, the whole mechanism builds level more and more high, to complicated curved stalk Duan piece and speech, not only the shape is complicated, and Duan piece size accuracy, the request of surface quality etc. also more strict, so investigate a light sedan complicated curved stalk Duan the reasonable forging method of the piece, seem to be is importance.Produce an actual need according to a the vapor light sedan, in experimenting a research of foundation, we adopted the Gun Duan system Pi-rub the pressure machine mold Duan compound craft to act for mold Duan of traditional hammer, the gave birth to light car turns to the left toward the stanza arm, the sedan of Ao Di is left and right under control arm etc. five kinds of complicated curved stalk Duan piece, its Duan piece the technique level come to a light car and the sedan of Ao Di original diagram paper to design a request, various index signs with economic techniques all come to an an expectation target.Two, craft analysis and project assuranceLight sedan complicated curved stalk Duan piece, its characteristics is a stalk line to present a space curve form and much cut noodles to differ and fall bad to the flection big, shape complicated, the forging takes shape to process a difficulty with molding tool bigger.With turn to the left toward the stanza arm(figure 1) is example, press mold Duan of traditional hammer craft, generally want to adopt to stir long-roll to press-flection-forging etc. the work tread.Its outstanding weakness is that the Duan piece accuracy is worse, while working vibrates noise greatly, material depletion and can consume greatly, labor condition bad.If the adoption more advanced hot mold Duan pressure machine takes shape a method, although the worker labors a condition well, rate of production and Duan piece size accuracy is higher, also easy to realization mechanization and automation, the its outstanding weakness is manufacturing cost Gao, inconvenience in pull out long, roll and press the etc. system Pi work and tread, need and go together with the other assistance equipments system Pi.Aim at many problems of the existing forging craft and the technique characteristics of the complicated curved stalk Duan piece oneself, we made sure Gun Duan-rub the pressure machine mold Duan compound forging craft of project, its craft process is:Next anticipate medium repeatedly respond heating the Gun Duan system Pi flection forging slice a side correct Duan piece quality examination.In this craft project adoption repeatedly responding heat not only raised Duan piece surface quality, stabilized craft process, also can raise rate of production, the improvement labors environment.Several time Gun Duan system Pi, can availably solve complicated and curved stalk Duan piece piece noodles bad great problem, make to make Pi shape to approach more in this launches behind of straight line shape and size, reduce a Duan piece to fly a side, save original material.In order to rubbing, the pressure machine tool has mold Duan the hammer and Duan presses machine of the dual work characteristic is rubbing pressure to carry on flection to take shape, prepare Duan on board, eventually Duan and correct to take shape, be advantageous to stable craft process, promise Duan piece quality, also have very high rate of production in the meantime.Three, technological design important point 1. The design of the semi-finished product of Gun DuanGun Duan semi-finished product design whether reasonable as to its empress of curve, forge to take shape a work preface to have to influence very greatly, should be accurate to make Pi, satisfy reasonable between work prefaces to match.In addition to pressing is general of Gun Duan the semi-finished product design a principle, notice following problem:(1)The gradient selection principle of the Gun Duan semi-finished product transition block for under the sistuation that can satisfy eventually the Duan been full of chamber, the gradient as far as possible obtains a little bigger, avoid a little bit greatly flying a side at the size head transition formation.(2)Because adoption the Gun Duan system Pi, rub pressure machine to take shape, at compute semi-finished product of horizontal piece area F=F +2 KF , fly a side the slot be full of coefficient K to take 0.40.6 then, according to Duan piece the shape size is more difficult than fill of part take big value, the part being easy to a fill takes a small value.(3)The calculation and selection of the extension coefficient of the Gun Duan system each way of Pi time, avoid the Gun Duan process way time occasionally Gun Duan empress of the semi-finished product appear to fold.2. The returning of flection playsTo complicated curved stalk Duan piece but speech, the flection takes shape to a pass importance.In the hot Duan, the flection has already denied a time to play in the process and related impact factor, introductive in the teaching material, design manual and data of few.Pass experiment research enunciation, at rubbed pressure to carry on on board dont clip tight flection, it is existent to curve back to play, hot Duan flection return to the size that play a value mainly and the shape of opposite flection radius R/t, work piece and molding tool, curve parts of Pis to anticipate to crush flat degree namely transform degree to contain greater relation.When R/t is more big return to play quantity also more big, work piece at curved mold in is crushed flat degree more big, bent type slot function the part is more long and return to play quantity more small.With turn to the left toward the stanza arm for example(figure 1), return to play while taking shape because of the flection of the influence , after the flection takes shape, open mouth size to enlarge a 56 mms, the flection Cape enlarges tofrom 102 s 103.4 s and curve semi-finished product with eventually the Duan type slot obviously and not and mutually match.Make the Duan piece fallen bad size while correcting mold flection to take shape, because of returning to the influence for playing 22+2.0+1.0 let up a 23 mms, if design take no account of a time to play a problem, will directly influence a Duan piece size accuracy and surface quality and material utilization.In the process of developing in, a little bit accurately made sure the flection time of different piece, different part after playing number, carried on a modification and obtained better effect at first to parts of designs.3. Curve the design of semi-finished productTo complicated and curved stalk Duan piece, flection semi-finished product design whether reasonable, to the forging take shape influence very greatly.Adjust to try in the craft in appear of two key problems BE:The bent semi-finished product puts go into eventually Duan type the slot is unsteady and easily be partial to put;The right angle bent place easy folds.Such as the 1 t light car left, turn to the right toward the stanza arm two kinds of Duans piece in the first design, after flection put to go into eventually a Duan type slot appear to be partial to pour a problem.Afterwards when the modification designed enlarged to bently crush flat degree, laid equal stress on to lately make sure bent semi-finished product with eventually the contact position of Duan type slot, make the bent semi-finished product stability put go into eventually Duan type slot.The right angle bent place easys folding this is widespreadly a technique problem that exists, such as figure 2 show.Because metal dynasty minimum resistance direction flows and then curves place to gather together in the right angle, result at Duan piece the essence and hair fold on formation of side.For control a Duan piece right angle flection place not folds, mainly should design the shape and size of good flection semi-finished product, it designs a key to want the R of right angle be worth to as far as possible take of a little bigger, and make bent place of right angle R outline line at eventually Duan type slot outside, such as figure 3 show, although eventually still keep producing to fold in the Duan process in the Duan piece,fold to only appear a side at the hair at this time up, not appear an essence at the Duan piece up.Practice a proof, want only flection semi-finished product design reasonable, ability with eventually Duan type the slot Be good to match, it is complete to can overcome right angle flection to fold a problem.4. Bent work preface of reasonable arrangementFor simple flection, namely a square upward of bent work preface, generally arrangement at crest Duan, eventually the Duan is previous, but for much more complicated to flection Duan piece, flection work preface of the reasonable arrangement is also very important, from forging equipments but speech, only have a perpendicular direction of sport, can arrange a square upward flection to take shape, in the research of this item, adopted much resolve toward the flection reasonable of technique measure.Such as the sedan of Ao Di left and right next pull the arm two kinds of Duans piece, not only the shape is complicated, and the Duan piece has on two directions 4 kinds of different of bent angle.To this, we while drawing up a craft, a square upward of bent type the slot opens in preparing a Duan mold, through the semi-finished product of the Gun Duan system Pi first through always curve and prepare Duan, another square upward of the flection arrangement of three kinds of different shape, different angle at eventually Duan work preface namely make use of eventually the Duan type slot complete flection and eventually the Duan take shape.Again if the 2 ts light car turns to the left arm(figure 1) toward the stanza wall, is also 4 kinds of two directions flection angles, and fall bad a little bit greatly, to this kind Duan piece pass by earnest of craft analysis, adopted the following craft project, at one pedestal friction the pressure carries on a level direction on board of the flection take shape, then at another one pedestal friction the pressure is on board eventually the Duan takes shape, after slicing a side again at correct mold full general perpendicular direction of the song form press out, like this not only make Duan mold eventually with slice a side mold shape simplification, process manufacturing difficulty to lower, economical molding tool material, and easily promise a Duan piece quality, through actual production usage enunciation, turn to the left is correct to the craft route of the stanza arm, carry on in correcting a mold perpendicular direction of flections taking shape is successful.Four, the molding tool reasonable structure and designIn order to rubbing the pressure machine route of travel speed hammer to compare with mold Duan, is slow, the molding tool is had by dint better condition, it accepts shot noodles generally for the hammer last mold Duan 1/3 then.In the design of this item, for prepare a Duan mold, eventually Duan mold, corrected a mold to all adopt to inset a piece of type molding tool structure, can a little bit significantly lower molding tool material, lower molding tool machine to process and expenses.In addition, in order to adapt to large numbers of requests that the quantity produces, the molding tool direction part adopts to leads pillar and lead structure, with equilibrium curved stalk Duan piece the mold Duan appear in the process of wrong the pieces moving dint, reducing Duan are wrong bad, raise Duan piece accuracy, also in the meantime easy to molding tool install adjust.Complicated and curved stalk Duan piece the piece noodles differs a little bit greatly, generally need through make the Pi work treads, in order to making semi-finished product in Pi to cut noodles shape and size very difficult with Duan piece mutually fit together, past while preparing Duan usually appear surplus metal to flow to in addition to mold Tang, make prepare a Duan mold, the dozen without resort to, in the Duan mold accept shot noodles the formation flies a side, preparing of mold Duan craft of hammer Duan not establish fly side slot, in the design of this craft, in preparing a Duan mold also establish fly side slot fly a side by making surplus metal flown to inside the slot, and make the molding tool beaten depend, thus and availably promise to prepare the shape and size of Duan semi-finished product, make prepare Duan semi-finished product cut area and eventually the Duan semi-finished product cut area match reasonable, promise a complicated Duan piece of good take shape, avoid folding wait blemish.Rub pressure to prepare the shape that the Duan flies side slot on board with eventually Duan homology, but want a big 1.52 mms in flying the side bridge department and Cang department highly, but the width want to shorten 45 mms.This design method for rub the pressure machine mold Duan to take shape is very reasonable. Five, conclusion(1) Adopt Gun Duan-rub the pressure machine mold Duan compound craft to produce complicated curved stalk Duan of light sedan piece, its product size accuracy Gao, surface quality good, with mold Duan of traditional hammer the craft compares, can economize original material on the average above 15%, can consume to lower 60%, Duan piece the economic efficiency and social efficiency that can descend above 10% than the cost, have to show Zhao.(2) This craft project choice reasonable, production line stability credibility, the technological design method in this text and molding tool structure design as to its it is complicated curved stalk Duan piece the technological design have universal instruction meaning.复杂弯轴压力机模锻复合锻造工艺摘要针对轻轿车复杂弯轴类锻件现有生产工艺的诸多问题及该类锻件自身的技术特点，本文提出辊锻摩擦压力机模锻复合工艺方案，介绍有关辊锻毛坯，弯曲毛坯，弯曲回弹，弯曲工序的合理安排等工艺设计要点及模具的合理结构与设计。经实际生产考核表明：本工艺方案先进合理，生产过程稳定可靠，经济效益显著。本文中的工艺设计方法对其它复杂弯轴类锻件有普遍参考意义。 关键词：复杂弯轴锻件 复合锻造工艺 轻轿车 一、前言 复杂弯轴类锻件的最佳成形法一直是锻造行业致力研究的问题，前些年我国轻轿车生产数量不大，没有形成规模经营，故轻轿车复杂弯轴锻件的生产主要以传统的锤上模锻工艺进行小批量生产，有的厂家甚至采用自由锻胎模锻工艺，需几火次才能锻成。近年来，我国轻轿车生产迅速发展，生产批量越来越大，整机制造水平越来越高，对复杂弯轴类锻件而言，不仅形状复杂，而且锻件尺寸精度，表面质量等方面的要求也更加严格，故探索轻轿车复杂弯轴类锻件的合理锻造方法，显得尤为重要。根据一汽轻轿车生产实际需求，在试验研究的基础上，我们采用了辊锻制坯摩擦压力机模锻复合工艺替代传统的锤上模锻，生产了轻型车左转向节臂，奥迪轿车左、右下控制臂等五种复杂弯轴类锻件，其锻件技术水平达到了轻型车、奥迪轿车原图纸设计要求，各项技术经济指标均达到了预期目标。 二、工艺分析与方案确定 轻轿车复杂弯轴类锻件，其特点是轴线呈空间曲线形，多向弯曲，截面差与落差大，外形复杂，锻造成形与模具加工难度较大。以左转向节臂(图1)为例，按传统的锤上模锻工艺，一般要采用拨长滚压弯曲锻造等工步。其突出缺点是锻件精度较差，工作时震动噪音大，材料消耗与能耗大，劳动条件差。如采用较先进的热模锻压力机成形法，虽然工人劳动条件好，生产率及锻件尺寸精度较高，也便于实现机械化和自动化，但其突出缺点是制造成本高，不便于拔长、滚压等制坯工步，需配其它辅助设备制坯。 图1针对现有锻造工艺的诸多问题及复杂弯轴类锻件自身的技术特点，我们确定了辊锻摩擦压力机模锻复合锻造工艺的方案，其工艺流程为：下料中频感应加热辊锻制坯弯曲锻造切边校正锻件质量检测。本工艺方案采用中频感应加热不仅提高了锻件表面质量，稳定了工艺过程，也可提高生产率，改善劳动环境。多道次辊锻制坯，可有效地解决复杂弯轴锻件截面差大的问题，使制坯形状更接近于这类锻件展开后的直线形状和尺寸，减少锻件飞边，节省原材料。由于摩擦压力机具有模锻锤和锻压机的双重工作特性，在摩擦压力机上进行弯曲成形、预锻、终锻及校正成形，有利于稳定工艺过程，保证锻件质量，同时也具有很高的生产率。 三、工艺设计要点 1.辊锻毛坯的设计 辊锻毛坯设计是否合理对其后的弯曲，锻造成形工序有很大影响，应精确制坯，满足工序间的合理匹配。除按一般的辊锻毛坯设计原则外，要注意以下问题：(1)辊锻毛坯过渡区段的斜度选取原则为在能满足终锻充满型腔的情况下，斜度尽量取得大些，避免在大小头过渡处形成较大飞边。(2)由于采用辊锻制坯、摩擦压力机成形，在计算毛坯的横截面积FF+2KF时，飞边槽充满系数K取0.40.6即可，根据锻件形状尺寸，难于充填的部分取大值，易于充填的部分取小值。(3)辊锻制坯各道次间的延伸系数的计算与选取，要避免辊锻过程道次之间或辊锻后的毛坯出现折叠。 2.弯曲的回弹 对复杂弯轴类锻件而言，弯曲成形至关重要。在热锻时，弯曲过程中有否回弹及相关的影响因素，在教材、设计手册及资料中介绍的很少。通过试验研究表明，在摩擦压力机上进行没有夹紧的弯曲时，弯曲回弹是存在的，热锻时弯曲回弹值的大小主要和相对弯曲半径Rt，工件及模具的形状，弯曲部分坯料压扁程度即变形程度关系比较大。当Rt越大时回弹量也越大，工件在弯模中被压扁程度越大，弯曲型槽作用部分越长，回弹量越小。以左转向节臂为例(图1)，由于弯曲成形时回弹的影响，在弯曲成形后，开口尺寸增大56mm，弯曲角由102增大到103.4，弯曲毛坯与终锻型槽明显不相匹配。在校正模弯曲成形时，由于回弹的影响，致使锻件落差尺寸22+2.0+1.0减小了23mm，如果设计时不考虑回弹问题，将直接影响着锻件尺寸精度和表面质量及材料利用率。在研制过程中，比较准确地确定了不同件、不同部位的弯曲回弹数值后，对原部分设计进行了修改，取得了较好的效果。 3.弯曲毛坯的设计 对复杂弯轴类锻件，弯曲毛坯设计是否合理，对锻造成形影响很大。在工艺调试中出现的两个主要问题是：弯曲毛坯放入终锻型槽不稳定，容易偏摆；直角弯曲处易出折叠。如1t轻型车左、右转向节臂两种锻件在最初的设计中，经弯曲后放入终锻型槽时出现偏倒问题。后来修改设计时，加大了弯曲的压扁程度，并重新确定了弯曲毛坯与终锻型槽的接触位置，使弯曲毛坯稳定放入终锻型槽。直角弯曲处易出折叠这是一个普遍存在的技术问题，如图2所示。 图2由于金属朝最小阻力方向流动，则在直角弯曲处汇集，结果在锻件本体及毛边上形成折叠。为控制锻件直角弯曲处不出折叠，主要应设计好弯曲毛坯的形状和尺寸，其设计关键是要把直角处的R值尽量取的大些，并使直角弯曲处R的轮廓线在终锻型槽外面，如图3所示，虽然在锻件终锻过程中仍然产生折叠，但这时的折叠仅仅出现在毛边上，而不是出现在锻件本体上。实践证明，只要弯曲毛坯设计合理，能与终锻型槽很好的匹配，是完全可以克服直角弯曲处折叠问题的。 图34.弯曲工序的合理安排 对于简单弯曲，即一个方向上的弯曲工序，一般安排在顶锻、终锻之前，但对于复杂多向弯曲锻件，弯曲工序的合理安排也是很重要的，从锻造设备本身而言，只有一个垂直方向的运动，只能安排一方向上的弯曲成形，在本项目的研究中，采取了把多向弯曲合理分解的技术措施。如奥迪轿车左、右下拉臂两种锻件、不仅形状复杂，而且锻件在两个方向上有4种不同的弯曲角度。对此，我们在制定工艺时，将一个方向上的弯曲型槽开在预锻模上，经辊锻制坯的毛坯先经一向弯曲并预锻，另一个方向上的三种不同形状、不同角度的弯曲安排在终锻工序即利用终锻型槽完成弯曲和终锻成形。再如2t轻型车左转向节壁臂(图1)，也是两个方向4种弯曲角度，并且落差较大，对此种锻件经过认真的工艺分析，采取了如下工艺方案，即在一台摩擦压力机上进行水平方向的弯曲成形，然后在另一台摩擦压力机上终锻成形，经切边后再在校正模上将垂直方向的曲形压出来，这样不仅使终锻模和切边模形状简化，加工制造难度降低，节省模具材料，而且容易保证锻件质量，经实际生产使用表明，左转向节臂的工艺路线是正确的，在校正模上进行垂直方向的弯曲成形是成功的。 四、模具合理结构与设计 由于摩擦压力机行程速度较模锻锤慢，模具受力条件较好，其承击面一般为锤上模锻13即可。在本项目的设计中，对于预锻模、终锻模、校正模均采用了镶块式模具结构，可较大幅度地降低模具材料，降低模具机加工时与费用。此外，为适应大批量生产的要求，模具导向部分采用了导柱、导套结构，以平衡弯轴类锻件模锻过程中出现的错移力，减少锻件错差，提高锻件精度，同时也便于模具安装调整。 复杂弯轴锻件截面差较大，一般需经制坯工步，由于制坯后的毛坯截面形状和尺寸很难与锻件相吻合，故在预锻时往往出现多余金属流往模膛外，使预锻模打不靠，在锻模承击面间形成飞边，锤上模锻工艺的预锻不设飞边槽，在本工艺的设计中，在预锻模上也设置了飞边槽，以使多余金属流向飞边槽内，并使模具打靠，从而有效地保证预锻毛坯的形状和尺寸，使预锻毛坯截面积和终锻毛坯截面积匹配合理，保证复杂锻件的良好成形，避免折叠等缺陷。摩擦压力机上预锻飞边槽的形状与终锻相同，但在飞边桥部及仓部高度上要大1.52mm，而宽度要缩短45mm。这种设计方法对于摩擦压力机模锻成形是很合理的。 五、结论 (1)采用辊锻摩擦压力机模锻复合工艺生产轻轿车复杂弯轴类锻件，其产品尺寸精度高，表面质量好，与传统的锤上模锻工艺相比，可平均节约原材料15%以上，能耗降低60%，锻件可比成本下降10%以上，具有显著的经济效益和社会效益。 (2)本工艺方案选择合理，生产过程稳定可靠，本文中的工艺设计方法与模具结构设计对其它复杂弯轴类锻件工艺设计具有普遍指导意义。作者单位：金明华 陈庆敏 寇淑清 金文明 吉林工业大学(130025) 参考文献 1张承鉴.辊锻技术.北京：机械工业出版社，1986. 2张志文.锻造工艺学.西安：西北工业大学出版社，1983