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利用Forge软件对大曲轴的镦锻成形进行有限元模拟,结果表明,模拟成形力和成形形状与实际结果不一致,通过对实际产品和生产情况进行分析,发现实际生产的曲臂比名义尺寸厚1 mm,在计算其成形力后,获得的模拟成形力与实际成形力仅差6.3%。曲臂形状的差异是由于在实际生产中坯料温度不均匀造成的,在使用模拟技术时,锻造技术人员应考虑实际生产中各种条件的变化,根据生产的实际情况对模拟结果进行综合分析。
The Forge software was used to simulate the upsetting forging of large crankshafts. The results show that the simulated forming force and forming shape are inconsistent with the actual results. By analyzing actual products and production conditions, it is found that the actually produced crank arm is thicker than the nominal one mm, after calculating its forming force, the obtained simulated forming force is only 6.3% lower than the actual forming force. The difference of crank arm shape is caused by the uneven temperature of billet in actual production. When using simulation technology, the forging technician should consider the changes of various conditions in actual production and make a comprehensive analysis of the simulation results according to the actual production.