高速列车制动盘盘毂锻造工艺数值模拟

基于实测的40CrA钢高温应力-应变曲线和热物性参数,建立了高速列车制动盘盘毂毛坯在模锻过程的有限元模型。运用DEFORM-3D软件,对该盘毂的多步骤锻造过程进行热力耦合模拟,得到了应力、应变和温度随时间的变化规律;研究盘毂成形过程的金属流动机制,模拟了产生折叠缺陷的位置;预测了盘毂完全成形所需的锻锤打击次数;对终锻模具的最大主应力进行分析,预测了模具在实际生产中可能产生的塌陷、开裂缺陷及其位置。根据模拟结果进行了生产试制,验证了工艺的可行性和模拟的准确性。

Numerical simulation for die forging of high-speed railway brake disc hub

Based on the measured stress-strain curves at different strain rates and the thermal-physical parameters of 40CrA steel,the finite element model for the forging process of a high-speed railway brake disc hub was established.The thermal-mechanical coupling process was simulated by using DEFORM-3D code.From the simulation results,the strain,stress and temperature field in the forging process were obtained.In order to simulate the folding defect position,the mechanism of metal flow of the disc hub was investigated.Furthermore,the number of combating for forging hammer was predicted.By analyzing the maximum principal stress on the final-forging mold,the collapse and crack that might arise in the actual production were predicted.The experimental results verified the feasibility of the process and the accuracy of the simulation.