Optimization Of Automobile Claw Pole Composited Die Structure And Process

Claw is not only an important part of automobile generator system, but also a kind of forgings with difficult forming and high requirements of precision. With the progress and development of automotive electrical technology, higher requirements are put forward to power generation performance of claw pole. At the same time, abnormal failure in precision forging such as cracks and wear of the claw forging die is also a production bottleneck, so how to improve the service life of forging die by developing the die structure and forging process of claw pole is key problem which needed to be solved for enterprise.First of all, this paper briefly introduced the forming process of claw pole and research status of claw pole precision plastic forming process home and abroad. A claw pole with convex platform was chosen as a typical forging part, 3D modeling software UG was used to design mold and finite element simulation software Deform-3D was used to simulate the forging process. Forming load curve of claw pole, max principal stress distribution of pre-forging die and wear depth distribution of precision forging were analyzed to explain the failure of forging die. According to failure of pre-forging die, three solutions of pre-forging composited die were put forward, and they are pre-stressed composited die, Convex platform-cavity-pre-stressed ring composited die, Convex platform-claw internal cavity-outside cavity-pre-stressed ring composited die. Comparing the simulation results of three schemes and it shows that mold craves can be fully filled, no forging defects will be generated, and the max principle stress of die could be greatly reduced in scheme two. In order to gain most reasonable composited die structure, multi-objective orthogonal experiment was designed and optimal pre-forging composited die structure was got. According to wear failure of precision forging die, GA-BP model was used to establish mapping relationship between forging process parameters and forming load, die wear. The reliability of GA-BP model which can provide the theoretical guidance to predict wear failure of precision forging die was confirmed by test sample. In the end, through trial production, optimal pre-forging composited die was verified with good forming performance and high die life.The precision forging process of claw pole, finite element simulation theory, multi-objective optimization model artificial intelligence were combined in this paper, and the research result achieves the following purpose: shortened the product development cycle, developed pre-forging die structure, improved the precision forging process and prolonged the die life, etc., The research in this paper can not only provide theoretical guidance for practical precision forging process of claw pole, but also provide technological support for designing and improving the precision forging process of other similar parts.