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针对传统模锻方法制造大榫头叶片工艺流程长、废品率高、尺寸精度低等弊端,提出挤压法制造叶片的工艺:挤压叶身和镦挤榫头形成叶片毛坯,后续机加工得到叶片产品。采用Deform-3D软件对挤压过程进行了数值模拟,优化了坯料形状、尺寸,分析了应力、应变分布,将叶身局部最薄处由R1 mm补偿为R6 mm,并采用偏心凹模法改变压力中心,解决了叶片成形过程中金属流动不均匀、开裂、弯曲等问题,并设计了挤压模具和镦挤模具结构。优化后的模拟结果表明:叶片挤压过程中金属流动性良好,成形精度高。
Aiming at the disadvantages of traditional die forging method for manufacturing large tenon blades, such as long process flow, high rejection rate and low dimensional accuracy, the paper puts forward the extrusion process of blade manufacturing: extruding blade and upsetting tenon to form blade blank, . Deform-3D software was used to simulate the extrusion process, and the shape and size of the blank were optimized. The stress and strain distribution were analyzed. The thinnest part of the blade body was compensated by R1 mm to R6 mm, and the eccentric die method was used to change The pressure center solves the problems of uneven metal flow, cracking and bending in the blade forming process, and also designs the extrusion die and upset extrusion die structure. The optimized simulation results show that the metal flowability is good and the forming precision is high during blade extrusion.