STEYR转向节模具参数优化及成形过程模拟-机械制造及其自动化专业论文.docxVIP

IV IV 摘要 转向节是通过挤压和锻压成形的，针对其复合成形特点，本文选择主应力法对斯 太尔（STEYR）转向节成形过程进行理论分析，用DEFORM软件进行材料变形、变形区应 力应变及模具受力的有限元模拟分析。优化了拔模角、过渡圆弧半径等模具参数,优选 锻压温度、坯料尺寸等成形参数。主要内容如下： 针对斯太尔转向节锻压成形过程成形特点，建立了基于主应力法的轴对称挤压、镦 粗以及具有过渡圆弧角轴对称挤压的分析模型，对斯太尔转向节锻压成形过程成形时坯 料变形区的应力应变规律进行研究，探讨坯料变形区的周向应变、径向应变变化特点， 探讨变形力变化规律。 在采用闭式模的情形下，设成形过程中加载条件为简单加载情形，材料本构关系服从 线性硬化规律，采用刚塑性硬化模型，成形过程中坯料的体积近似不变，应用 DEFORM 软 件对斯太尔转向节预锻成形过程进行了模拟。探讨模具杆部锥度及过渡圆角半径对成形过 程的影响。研究表明：杆部锥角 10o 较合适，过度圆角半径取 5mm 为宜。 应用 DEFORM 软件对斯太尔转向节终锻成形过程进行模拟分析，建立成形模型，通过 有限元分析计算，模拟锻造和挤压复合成形过程中金属的流动规律以及不同模具参数对坯 料金属流动规律的影响，探讨在成形过程中上模腔拔模角以及坯料尺寸、成形温度对成形 过程的影响。研究表明：终锻上模拔模角取 4o、锻件镦头初始截面半径取 125mm、锻压温 度取 1323℃比较合适。 关键词：转向节,锻压成型,主应力法,DEFORM,参数优化 ABSTRACT ABSTRACT v v Steering knuckle is manufactured by Extrusion and Die-forming process. In this thesis, using Stress-Principal Method, the forming process was analyzed theoretically and simulated by DEFORM software, the mould parameter such as the mould angle and the transition arc radii, the forming parameter as the forming temperature and the workpiece dimension had been analyzed and optimized. As concerned the STEYR knuckle forming characteristics, according to the stress-principal method several models were built up to analyses the axis symmetry extrusion, upsetting and the transition arc axis symmetry extrusion analytical model, discussing the transform area strain-stress characteristics and the forming force transforming regulation. Base on this postulate the forming area circumference and radial strain characters were discussed. And so the forming force transforming regulation was studied. In the closed die case, the forming condition is simple loaded and the strain-stress relationship is linear harden, use the rigid-plastic model and presume the volume was approximately constant when it was forming. Using the DEFORM software the steering knuckle pre-forming processes was simulated. The influence to the forming process by the die taper and transition arc radii were discussed. The results show that the die cone angle 1