Numerical Simulation And Process Optimization Study On Co-extrusion Process For Flange Forgings

Flange products are one of the key parts widely used in transportation,light industry,aerospace and other fields.They have the function of transmitting torque and bearing interface connection.Their quality directly affects the performance of the whole transmission system.Although there are many kinds of flange parts,their structural characteristics and technological process are similar.In the traditional process,the flange parts are usually hot formed from the blank to the final forming process,which is relatively easy to use,but it is easy to cause the shortcomings of low precision of finished parts,large material loss and so on.Therefore,in this paper,the forming process characteristics of flange forgings are analyzed,and the typical flange tripod flange is taken as the research object,the hot-cold composite forming process is taken as the design idea,combined with the DEFORM-3D finite element numerical simulation analysis and response surface numerical calculation method,the new process idea is studied and analyzed.Based on the analysis of the structural characteristics and forming process characteristics of flanged forgings,the design idea of hot and cold composite forming technology is put forward.Firstly,two kinds of forming process schemes are proposed for flanged forging: single hot forming process and hot and cold composite forming process.Taking the typical flanged tripod flanges as the research object,the finite element software deform-3d was used to conduct numerical simulation of the forming process of the two technological schemes,and the cloud images of forming load,equivalent strain stress,folding Angle,damage factor and temperature field were obtained.By comparing and analyzing the numerical simulation results of the two technological schemes,it is determined that the hot and cold composite forming technology is suitable for the production of flanged forgings.Secondly,the blank making,preforming and final forming process of tripod flange forming process were simulated numerically.By analyzing the physical field distribution of forming load,equivalent stress and damage factor at different steps in the simulation process,the metal deformation and forming defects in the forming process are explored.Based on Archard wear model,the die wear during the final forming of tripod flange was studied and analyzed,and the influence of different technological parameters on the die wear degree was discussed.In the forging process,there are many technological parameters that have influence on the forming effect,and response surface method can optimize many technological parameters.Therefore,in this paper,according to the technological characteristics of tripod flange preforming and final forming processes,response surface analysis was carried out on the technological parameters influencing the preforming and final forming processes of tripod flange forgings respectively with the help of response surface test method and deform-3d software to determine the optimal combination of technological parameters.Finally,according to the wear condition of the tripod flange final forming die,the rounded corner radius of the punch die in the final forming process of the tripod flange was optimized.The rounded corner radius was obtained by comparing the final forming effect of four groups of different rounded corner radius,and the die bore and the whole die were designed.The research content and results of this paper provide theoretical reference and technical guidance for forging production and die design of flanged forgings.