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针对花键轴叉锻件传统锻造工艺耗料多的问题,提出立式预锻、杆部热挤成形的预锻成形方法,给出了立式预锻的模具结构设计,并对热挤预锻模具进行了参数优化,解决了充填不足的问题,最终锻出低能耗、低料耗、高生产率的合格锻件。基于Deform-3D有限元分析软件模拟观察到花键轴叉锻件的成形过程,准确分析出缺陷形成的原因和工艺优化后锻件成形效果。通过实际生产验证了模拟结果的可靠性,在优化预锻件脱模斜度和终锻模具桥部参数后,生产效率提高至少20%,料耗节省约15%,终锻模具磨损量降低约25%,模具寿命得到明显提升。
Aiming at the problem of more forging materials in traditional forging process of spline shaft forgings, the method of vertical pre-forging and the hot-forming of rod parts are proposed. The design of the mold for vertical pre-forging is given. The parameters of the mold are optimized to solve the problem of insufficient filling, and finally forged low-energy, low material consumption, high productivity forgings. Based on the Deform-3D finite element analysis software, the forming process of the splined shaft forgings was observed and the reason for the formation of defects and the forming effect of the optimized forgings were analyzed. Through the actual production, the reliability of the simulation results is verified. After optimizing the demoulding slope of the preform and the final bridging die bridge parameters, the production efficiency is improved by at least 20%, the material consumption is saved by about 15%, and the final forging die wear is reduced by about 25 %, Die life has been significantly improved.