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针对G2500曲轴的曲柄宽度较大、模锻时很难充满的特点,采用先辊锻制坯、再模锻成形的工艺进行加工。通过数值模拟对设计的4种G2500曲轴辊锻件的模锻过程中的金属流动情况及压力机吨位的变化进行了模拟分析。在保证模锻型腔填充良好、曲柄充满、所需模锻设备吨位满足的情况下,确定了辊锻件4为合理的辊锻毛坯。最后通过实际生产对模拟结果进行验证,结果表明,实际生产结果与模拟吻合,采用合理的辊锻件尺寸,可以在8000 t热模锻压力机上获得质量良好的G2500曲轴。
In view of the larger crankshaft width of C2500 crankshaft and the difficulty of being filled during die forging, the first roll forging billet and then die forging process are processed. Through numerical simulation, the flow of metal and the change of tonnage of press during the forging process of four kinds of G2500 crankshaft roll forgings were simulated. Under the condition of ensuring that the forging cavity is filled well, the crank is full and the required forging equipment tonnage is satisfied, it is determined that the roll forging 4 is a reasonable roll forging blank. Finally, the simulation results are validated by actual production. The results show that the actual production results are in good agreement with the simulation. The reasonable size of roll forging can be used to obtain the good quality G2500 crankshaft in 8000 t hot die forging press.