铝合金空调压缩机斜盘闭式模锻成形数值模拟研究

目的 探索不同结构模具下斜盘的成形过程,解决斜盘圆环棱角易充填不满的缺陷问题.方法 利用Deform对斜盘在无冲孔连皮及单向/双向冲孔连皮模具下的成形过程进行数值模拟分析,根据模拟结果选择最优模具结构并进行实验验证.结果 在斜盘成形阶段,载荷缓慢上升,金属稳定流动充填大部分模腔.在斜盘整形阶段,载荷快速上升,金属将斜盘圆环棱角充填完整,在圆环棱角处形成应力集中.双向冲孔连皮成形能有效降低成形载荷(从340 t到250 t),且其应力集中及损伤较大区域可经机加工完全去除,为最优的成形方式,其模拟结果与实验结果相符合.结论 经实验验证双向冲孔连皮模具结构为成形斜盘的最优方式.

Numerical Simulation of Closed-Die Forging for Aluminium Alloy Swashplate of Air Conditioning Compressors

The work aims to explore the forming process of swashplates of different die structures and solve the defect that the corners of the swashplate are not easy to fill up. The forming process with dies of no-punching wad, one way-punching wad and two way-punching wads were numerically simulated with Deform software, and the best mould structure was selected to conduct experimental verification according to the simulation results. During the forming stage of the swashplate, the load slowly increased while the metal flowed steadily and filled the majority of the cavity. During the shaping stage, the load increased quickly and the corners of the swashplate ring were filled, stress concentration was formed at the corners of the ring. Two way-punching wads could effectively reduce the forming load from 340 t to 250 t, and the stress concentrations and large damage areas could be completely removed by machining, so it was the best forming method. The simulation results were consistent with the experimental results. The two-punching wad is the best way to form the swashplate proven by experiment.