349-paper-B7-大型叶片等温成形的计算机模拟与分析.docVIP

编号：B7（中文全文） 吴瑞恒，庞克昌 （宝钢特殊钢技术中心，上海 200940） 摘要：在DEFORM 3D有限元分析软件平台上，对大型叶片的等温成形过程进行了计算机模拟与分析，并根据模拟结果对坯料的形状和尺寸、定位及成形工艺进行了多次修改。最后认为坯料最好为扁平状，这样的坯料也可以在下模模腔内正确定位，且没有成形缺陷。模拟结果还显示锻件叶型和榫头部位的等效应变值比较均匀，说明修改后的成形工艺更合理、更优化。计算机模拟与分析为坯料、锻件的优化设计和成形工艺的制定提供了有力的依据和参考，缩短了大型叶片等温成形的开发周期，节省了大量的试制试验和昂贵的原材料，因此大大降低了产品开发和制造成本。实际锻件与模拟结果比较一致。 关键词：大型叶片成形；等温锻造；计算机模拟 Computer Simulation and Analysis on the Isothermal Formation of Bigger Vane Forging Wu Ruiheng， Abstract: On DEFORM 3D FEM software platform, computer simulation and analysis on the isothermal formation of the big vane forging is performed. According to the simulation results, the shape and size of blank, the position of the blank, and the formation process are modified for many times. At last, the flat-shape blank is perfect, and could be positioned rightly on the lower die and display no shaped defects. The simulation results also showed that the effective strains in the forging leaf part and rabbet part are uniform, which imply that the optimized process is more reasonable. The computer simulation provides the theoretical foundation and reference for the forging design and forming process determination. It shortens the period to develop the isothermal formation of the big vane forging and saves a mass of trial test and expensive materials. Thus, the development and manufacture cost are greatly reduced. The factual forging is same as the simulated one. Keywords: Big vane formation; Isothermal forging; Computer simulation 0 前言 叶片的等温模锻工艺是20世纪末期发展起来的大型叶片成形工艺。由于叶片型面复杂，且精度要求高，所以对锻件还要进行大量数控加工。为减少锻件的数控加工量，必须提高叶片锻件的尺寸精度，尽量减少加工余量。。 图2 TC4高温流变应力曲线 (a) 800℃，(b) 900℃，(c) 1000℃ Fig.2 Curves of flow stress of TC4 at high temperature (a) 800℃, (b) 900℃, (c) 1000℃ 1.3 温度场的处理 锻件成形工艺为等温锻造。实际成形过程中模具与锻件的温差很小，而且采取了隔热措施，锻件和模具的热量损失都很少。因此，计算中简化了温度场模型，认为变形过程中模具和锻件的温度始终保持不变。 2 坯料设计与成形工序模拟 2.1 坯料设计 对圆棒坯料的一次成形过程模拟结果显示，初始的金属分配很重要。如果初始的金属分配不合理，金属很难完全充满模具。如图3所示，当榫头已完全充满模具时，叶尖部分还差很多。这样会造成大量金属从榫头部分长距离流向叶尖，势必会引起载荷的大幅增加，并降低模具的使用寿命。 根据锻件金属分配，经多次修改、模拟，最后认为坯料形状最好能如图4所示的形状