大型船用曲轴TR法镦锻成形缺陷分析
Forming Defect Analysis and Process Optimization of Heavy Marine Crankshaft Formed by TR Upsetting-bending
徐戊矫， 朱若岭， 周 杰
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作者单位：重庆大学 材料科学与工程学院，重庆 400044
中文关键字：大型船用曲轴； TR法镦锻成形； 成形缺陷分析； 模具结构优化
英文关键字：heavy marine crankshaft; TR upsetting-bending process; forming defect analysis; die structure optimization
中文摘要：大型曲轴是大型内燃机的关键零件。针对我国大型船用曲轴锻造中存在的精度低、加工余量大等问题，采用DEFORM-3D软件对其TR镦锻过程进行了数值模拟仿真。通过模拟分析曲轴成形的塑性流动规律，找出了大型船用曲轴曲拐成形过程中的典型缺陷连杆颈和曲柄臂外侧折叠的成因。研究发现，弯曲下模和预锻模设计不合理是造成曲轴锻件折叠缺陷的主要原因；并在此基础上优化了锻件成形的工艺方案,从而为大型曲轴镦锻模具设计提供了科学依据。生产试验表明，采用新的模具结构设计方案，可以有效避免大型曲轴镦锻时的折叠缺陷，所成形的曲轴质量良好。
英文摘要：The heavy crankshaft is the key component of large diesel engine. Aiming at the low precision and big machining allowance in the heavy crankshaft's forming, the heavy crankshaft's forging process was simulated by DEFORM-3D software. Based on the analysis of plastic flow law in crankshaft forming, the cause of typical forming defects, i.e. the folding existing in the crankshaft pin and crank arm was found out. It is shown that the improper design of bending lower die and pre-forging die is the main cause of crankshaft's folding; so the forming process for the heavy crankshaft is optimized accordingly, which is the scientific basis of die design. Experimental results show that the forming defects existing in the heavy marine crankshafts could be eliminated and the high-quality crankshaft could be forged by the utilization of optimal die structure parameters.