Deformation Force Modeling For The Whole Complex Forging Process And Its Verification

With the development of modern aerospace and aviation technology, the development trend of the new generation of aviation forgings is larger, more sophisticated, more overall, and it is a new challenge for the forging technology. The isothermal forging process on large forging presses is an feasible way to achieve this goal, but it requires the accurate and stable operation of large die forging equipment. While the forming process of large-scale forging is a continuous, complex, nonlinear and rheological process, and it leads to strong nonlinear deformation force, which seriously affects the control precision of forging equipment. Thus, a real-time modeling method of deformation force in the whole complex forging process is important, which provides the basis for accurate and stable operation of large forging equipment. The main research contents are following:1) A time/shape decomposition modeling method is proposed for complex forging process. The complex forging process is first decomposed into a group of simple sub-processes using system knowledge. At each sub-process, its complex geometric shape is further decomposed into many easily modeled units, which are modeled by the main stress method. All sub-models are integrated by using the continuity condition between two adjacent sub-units and two adjacent sub-stages. Moreover, unknown parameters of the integration model can be identified online using online input-output data of large forging equipment. Finally, the load model of complex forging processes has been achieved, which provides the basis for accurate and stable operation of large forging equipment.2) The model of deformation force of revolving forging in the whole forging process is modeled and verified by simulation. The models of deformation force of simple revolving forging and complex revolving forging are modeled by the time/shape decomposition modeling method, which are verified by simulation software named DEFORM, and the results show that:the models of deformation force of revolving forging and simulation data are basically tallies, and the time/shape decomposition modeling method is accurate and effective.3) The model of deformation force of complex flat forgings in the whole forging process are modeled and verified by simulation and experiment. Firstly, the model of deformation force of long blank of complex cross section is modeled by the time/shape decomposition online modeling method, and verified by DEFORM, which shows that:the models of deformation force of long blank of complex cross section and simulation data are basically tallies. Secondly, the time/shape decomposition online modeling method is verified by the experiment of aviation joint, and the experimental results show that:the model of deformation force of aviation joint and experimental data are basically tallies. Therefore, both simulation and experiment prove that the time/shape decomposition modeling method is accurate and effective.Full total figures50, tables4, reference78...