基于数值模拟的7075铝合金转向节成形工艺优化
Optimization of Forming Process for 7075 Aluminum Alloy Steering Knuckle Based on Numerical Simulation
李海荣1， 邹明平2
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作者单位：（1.四川工程职业技术学院 材料工程系，四川 德阳 618000; 2.重庆大学 材料科学与工程学院，重庆 400044）
中文关键字：7075铝合金； 转向节； 辊锻； 工艺优化； Deform
英文关键字：7075 aluminum alloy; steering knuckle; roll forging; process optimization; Deform
中文摘要：应用三维有限元模拟软件Deform对7075铝合金转向节成形过程进行了数值仿真与工艺分析。通过模拟研究，确定该转向节的成形方案为：二道次辊锻制坯加一步终锻成形。在辊锻制坯时，将原始圆坯优化为方坯显著地提高该过程的稳定性，进而改善了辊锻制坯件的质量。针对转向节较难成形部位，将辊锻以及终锻模膛结构作适当修改。改进后，所得终锻件各部位充填饱满、飞边分布均匀并且无明显折迭缺陷。实际生产表明，采用优化后的工艺成形的铝合金转向节质量良好，符合产品的使用要求。
英文摘要：The numerical simulation and process analysis were used to investigate the forming process for 7075 aluminum steering knuckle based on FE software Deform. The final forging process was determined as two passes roll forging and one step finish forging process. The initial round billet was optimized as the cube shape to increase the stability of the roll forging process and make the further improvement of the roll forging billet's quality. The structures in the roll forging die cavity and finish forging die were adjusted to solve the main forming defects, and then the simulation was conducted. The results shows that the forging part has better filling die, even flash and has not fold defect. The practical production indicates that 7075 aluminum steering knuckle can get excellent forming quality and meet the appliance requirement.