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大型厚壁封头严苛的使用性能要求其采用整体锻造方法生产,但锻造企业通常不具备足够的设备能力以满足封头整体锻造超高的力能需求。基于刚粘塑性有限元模拟平台DEFORM-3D,对大型厚壁封头上砧旋转锻造成形原有的工艺方案进行了模拟仿真,分析了产生折迭缺陷和锻造载荷超限的原因。优化上砧形状为马鞍型,并确定上砧的运动轨迹为单周压下量为100 mm,每压下一次后上砧旋转角度为24°。对优化后的工艺方案进行仿真计算。结果表明,工艺优化有效地将所需的成形载荷降到了设备能力允许的范围之内,并使整体锻造的封头无折迭缺陷。研究结果对提高封头整体锻造的可行性及改善大型厚壁封头的成形质量具有重要的指导意义。
The severe serviceability of large, thick-walled headers requires their use of a monolithic forging method, but forging companies often do not have sufficient equipment capacity to meet the overall forging power requirements of the headers. Based on the rigid-viscoplastic finite element simulation platform DEFORM-3D, the original technological scheme of rotary forging of an anvil in a large thick-walled head was simulated and the reasons for the occurrence of folding defects and forging load overrun were analyzed. The shape of the anvil was optimized to be a saddle type, and the moving path of the anvil was determined to be 100 mm per cycle. After each press, the rotation angle of the anvil was 24 °. The optimized process scheme is simulated. The results showed that the process optimization effectively reduced the required forming load to within the allowable range of equipment capacity and resulted in an integral forged head without folding defects. The results of the research have important guiding significance for improving the feasibility of integral head forging and improving the forming quality of large thick-walled head.