车用2A12铝合金连接锻件变形规律分析与工艺设计

针对某种2A12铝合金车用连接锻件质量差,容易报废的问题,利用Deform仿真系统对该锻件的变形过程进行了模拟分析.根据模拟结果可知,锻件易报废是由于材料相对流动产生折叠引起的.鉴于此,在原工艺基础上增加了预锻工序,预成形后有效消除了材料的折叠缺陷.但同时又出现了锻件顶部枝叉充不满的缺陷,因此对锻模进行了优化,引入了阻...

Deformation analysis and process design of 2A12 aluminum alloy connecting forgings for vehicles

To tackle the problems of poor quality and easy scrapping of a type of 2A12 aluminum alloy connecting forging for vehicles, the deformation process of the forging was simulated and analyzed by using the Deform simulation system. Simulation results show that the folding defect induced by the relative flow of the materials caused the easy scrapping of the forging. In view of this problem, the pre-forging process was introduced on the basis of the original process, which could effectively eliminate the folding defects of the materials after pre-forming, whereas the defect of insufficient filling of branches and forks occurred on the top of forging. Thus, the forging die was optimized, and the structures of resistance ditch and resistance wall were proposed. The influences of the two kinds of flash groove structures on filling improvement and forming force change were analyzed, and then verified by combining with actual forging test. Results show that by using the resistance ditch structure, the filling defects were only improved, but could not be completely solved. While with the introduction of the resistance wall structure, after forging the pre-formed blank, the forging was obtained with full filling and no folding defects, which successfully solved the problems existing in the original process.