基于PLC的电气控制系统在快速锻造压机中的应用

快速锻造油压机是广泛应用于冶金行业的重要设备,具有锻造速度快、锻件精度高、自动化程度高等特点,是目前国内外快速锻造压机的发展趋势。文章从电气控制角度,介绍了实现快速锻造压机高精度控制的编程方法。     

十字轴胎模锻造工艺

分析十字轴的特点和胎模锻造工艺,并设计了用于锻造的胎模模具,分析了经济效果。对类似零件的锻造模具设计提供了参考,具有一定的实际指导意义。     

2A14铝合金等温模锻成型技术

采用2A14铝合金等温模锻成型轮毂,研究模具设计、材料规格、锻造温度和热处理等工艺参数对合金力学性能及组织的影响,并与普通锻造的力学性能及组织进行了对比。2A14铝合金等温锻造态下的组织比普通锻造的组织明显细化,力学性能得到了显著提高;此外,采用该工艺锻造出的轮毂,具有尺寸精度高、工艺稳定、成型快速、材料利用率高和生产效率高等优点,具有极高的工程价值和发展前景。     

17Cr2Ni2MoVNb钢直齿轮精密锻造成形技术研究

研究了不同锻造比及正火温度对17Cr2Ni2MoVNb钢材料的力学性能、晶粒度及带状组织的影响,获得锻造比越大(变形量大),正火温度越高,带状组织及晶粒度越优;同时随着锻造比增加,屈强比有一定的下降趋势,这对于直齿轮精锻成形原材料尺寸的选择具有重要意义。通过分析不同锻造工艺对直齿轮精密成形的优缺点,开展直齿轮锻件及模具设计,以及直齿轮闭式锻造工艺仿真分析,完成了闭式锻造成形模具加工,并实现了直齿轮锻件的制造。结果显示,采用闭式锻造工艺可实现企业所用模数直齿轮的小批量生产制造,零件的锻造流线完整,符合锻造成形过程状态。     

单榫头叶片锻造过程成形缺陷分析

折叠和模腔充不满是锻造过程中常见的成形缺陷 ,利用自行开发的叶片锻造过程三维刚粘塑性有限元模拟分析软件 ,通过对叶片锻造过程不同截面金属流动规律的三维有限元模拟分析 ,可以预测叶片锻造过程成形缺陷折叠和充不满的形成。通过改变毛坯尺寸和成形工艺参数 ,可以消除这些成形缺陷的产生 ,并获得合格叶片锻件。该研究对其它种类叶片锻造过程中成形缺陷的分析具有一定的指导意义     

双立柱斜置式自由锻造液压机本体结构特征及安装

72MN/80MN双立柱斜置式自由锻造液压机目前是国内已投产的最大的快速锻造设备,用于特大型锻件的生产制造.该型锻造压机采用预应力框架结构,设计先进,具有良好的可操作型.文中主要阐述该机组本体的结构特征以及装配预紧方法.     

卸扣索具质量要求与锻造工艺

韧性高，纤维组织合理、性能变化小是卸扣索具进行锻造加工的主要原因，锻造后的卸扣具有最佳的综合力学性能，内部质量几乎不会被任何一种金属加工工艺超过。本文根据自己长期金属锻造工艺经验，对卸扣索具质量与检测及卸扣锻造工艺流程等进行了详细介绍。     

4CrMoTi钢的锻造工艺研究

4CrMOTi合金钢可以作为各类黑色和有色金属的冷轧机的工作辊和中间辊。该合金具有较高的抗断裂、抗剥落、耐磨损、高硬度和较深的淬硬层。本文从4CrMoTi的化学成分分析、锻造比的选择、锻前热处理、锻造加热规范、锻造过程,以及锻后热处理几个方面对该钢的锻造工艺进行研究。     

锻造工艺计算机辅助系统的设计

针对锻造行业中手工工艺编制的周期长、不精确的特点，通过Visual Foxpr05．0（企业版）软件系统的开发，利用Visual Foxpro直观、操作简便的特点，实现锻造工艺中典型的锻造工艺的编制和输出打印，从而大幅度提高工作效率，减少人为误差，节省原材料。同时，也为锻造工艺编制的系统化管理提供了思路。实践证明，用本系统设计计算出的锻造工艺与实际生产相符合，说明该系统具有一定的可靠性、可行性，适用于以锻为主的大中型锻造行业。     

下联板的摩擦压力机锻造工艺

下联板作为摩托车重要的部件之一，其锻造工艺具有一定的典型意义。本文通过对摩托车下联板的摩擦压力机锻造工艺和模具设计要点的分析和介绍，总结了下联板类典型锻件的锻造工艺。     

Comparison between cold rotary forging and conventional forging

Cold rotary forging is an innovative incremental metal forming process, which is obviously different from the conventional forging process in many aspects, such as the metal flow, degree of inhomogeneous deformation of workpiece and force and power parameters. In the current work, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of a cylindrical workpiece is developed under the ABAQUS software environment and its validity has been verified by the experiment. Based on the reliable 3D FE model, the cold rotary forging and conventional forging process are simulated and their difference in the forming process has been thoroughly clarified. The research results may help to understand the cold rotary forging process better. Furthermore, they provide valuable guidelines for further theoretical analysis and experimental studies on the cold rotary forging process.     

10MN液压精锻机锻造箱的结构优化设计

运用FEM解析对10 MN四锤头液压精锻机的主要零部件锻造箱进行结构强度有限元分析,并以减小锻造箱处应力为目标对锻造箱进行结构优化设计.以锻造箱各尺寸参数作为优化设计变量,以断裂处单元应力最小为优化目标,编制锻造箱优化设计程序ODPST,对锻造箱进行结构的优化.通过优化使锻造箱危险点应力减小约15.5%,锻造箱的强度提高效果明显,延长了其使用寿命.     

Impedance analysis of forging process and strategy study on compliance for forging manipulator

In the field of heavy forging, there are numerous researches on deformation rule in forging process by FEM simulation, however, not many scholars take the equipment constraint and the mutual reaction load between the forging manipulator clamp and the forging blank into account, which will impact on safety of manipulator body and quality of forging blank. This paper presents an impedance model to describe the load and formulates compliance strategies correspondingly to reduce the mutual reaction load for forging manipulator. Firstly, an FEM model of forging process is built. Meanwhile, the clamp of forging manipulator is added to the model as movement constraint and interaction part between the manipulator and the forming process. Secondly, a typical forging process is simulated by changing the movement constraint, and then an impedance model is established to describe the relationship between the load and movement constraint. Finally, two kinds of compliance strategies are formulated according to the impedance model, one is called free compliance, and the other is initiative/passive compliance. The simulation results show that compliance strategies reduce the load amounting to 5 000 kN in z direction between the manipulator clamp and the forging blank obviously, which may lead to serious accidents, such as the capsizing of forging manipulator, the fracture of manipulator clamp, and so on. The proposed research simulates the more real forging process, gets the initiative/passive compliance strategy which is more simple and suitable to the real producing and better for forming a forging process planning and control system in the modern production, and improves the quality and efficiency of heavy forging.     

A parametric study on residual stresses and forging load in cold radial forging process

In this work, a comprehensive study of radial forging process is presented through 2-D axisymmetric and 3-D finite element simulations while considering internal tube profile. The tube used in this investigation has four internal helical grooves along its length. The material is modeled with the elastic-plastic behavior, and sliding-sticking friction model is utilized to model the die-workpiece and mandrel-workpiece contacts. The numerical results in the 2-D case are compared with available experimental data. Residual stresses in the forged product, stress concentration around the grooves, pressure distribution on the hammers and mandrel and maximum forging load are studied. The effects of process parameters such as workpiece and die geometries, percentage of deformation, and workpiece motions on residual stresses and applied pressures on the hammers and mandrel are investigated. The results provide a valuable insight into the parameters affecting radially forged products and provide a useful tool for better design of this process.     

The forging of helical gears (II): comparisons of the forging processes

In this study, the forging processes of helical gears have been investigated wherein they have been classified into two types: the guiding type and the clamping types. These two types of forgings of helical gears have been analyzed by using the upper-bound method. New kinematically admissible velocity fields of the clamping-type forging of helical gears have been proposed, where an involute curve has been introduced to represent the tooth profile of the gear. The proposed velocity fields of the clamping-type forging of helical gears have been applied to the non-symmetric lateral extrusion forging and the result has been compared with the solution proposed by Plancak et al. [J. Mater. Process. Technol. 1992; 34:465–472]. Numerical calculations have been carried out to investigate the effects of various parameters, such as modules, number of teeth, helix angles and friction factors on the clamping-type forging of helical gears. For the forging of helical gears, the results of the upper-bound analysis of the clamping type have been compared with those of the guiding ones. Some experiments of the clamping-type forging were carried out with commercial aluminum alloy to show the validity of the analysis. Good agreement was found between the predicted values of the forging load and the experimental forging load.     

Vibrational activity of forging hammers

Theoretical and experimental data for the vibration-damping systems of forging hammers are compared.     

The prediction of maximum forging load and effective stress for different material of bevel gear forging

The manufacture of gears by applying hot or cold bulk forming processes is a quite widespread production method due to its well-known basic advantages such as material and time cost reduction and the increased strength of the teeth. However, the associated process planning and tool design are more complicated. In the precision forging of gears, the workpiece volume, the die design, the power requirement and careful processing are more critical than traditional forging technology. For complete filling up, predicting the power requirement is an important feature of the near net-shape forging process. In this paper, a finite element analysis is utilized to investigate the material properties such as yielding stress, strength coefficient and strain hardening exponent effects on forming load and maximum effective stress. The adductive network was then applied to synthesize the data set obtained from the numerical simulation. The predicted results of the maximum forging load and maximum equivalent stress of bevel gear forging from the prediction model are consistent with the results obtained from FEM simulation quite well. After employing the prediction model one can provide valuable references in prediction of the maximum forging load and maximum equivalent stress of bevel gear forging under a suitable range of material parameters.     

船用锻件的质量控制

根据各船级社规范中对产品质量的有关要求，结合生产实践经验，对船用锻件的质量控制进行了探讨。     

锻造生产线传送机的改进

针对旧板簧传送机故障率高、耐冲击性差、维修困难的状况,对其进行了优化设计,将新刮板传送机应用到实际生产中,减少了锻件生产中停时间,提高了生产效率。     

模锻多余金属分流腔

阐明了设置分流腔的机理，分流腔的设置原则以及分流腔的结构型式，为闭式模锻设计开拓不新的思路。