Finite element analysis and improvement of forging mould for crankshaft
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The finite element method was used to analysis the stress in the forging mould of crankshaft blank to solve the long existed problem of the forging mould short working life.A combined structure forging mould was designed and the parameters were determined according to the results of the analysis.The working life of the combined structure mould was several times longer than the original mould.It indicates that the improvement of the mould structure is significant and it is important to use the finite element method in mould design.Keywords:
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The course of cold extrusion of the star sleeve workpiece is simulated by the 3-D elasto-plastic coupled thermal-mechanical FEA method,using the advanced nonlinear FEA analysis software-MSC.MARC.The stress distribution on the mould is obtained;Then the result is analyzed and a method to reduce the concentration of the stress is found,and so the structure of the mould is modified;The structure is analyzed again based on the new model.The result make a good agreement to the practice and the serve life of the mould is prolonged obviously.This article plays a guiding role on the aspects of simulating the cold extrusion,controlling of the technical parameter and improving the life of the mould.
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The structure strength finite element analysis of the forging box of 10 MN four hammer precision hydraulic forging machine was carried out by using ANSYS software,optimal structure design for the forging box was carried out by taking the stress at the forging box as the object.By taking the various dimension parameters as optima design variables and taking minimization of the unit stress at fracture as the target,the optimum structure design program(ODPST) for the forging box was made to carry out optimization of its structure.Through the optimization of forging box structure,maximum stress at fracture is reduced by 15.5%.The improvement effect of the forging box strength is obvious, prolonging its life operation.
Hydraulic press
Hammer
Optimal design
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In the paper, by rigid-plasticity finite element software Deform-3D, the hot forging process of the crankshaft is analyzed under different technologic conditions. The results indicate that the pivotal data obtained by the finite element simulation has a good agreement with the practical productions and can be supplied to the practical production. The time of die trial and the costs of production can be reduced to a great extent and the production efficiency can be improved.
Production efficiency
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Using Forge 2D/3D forging finite element simulation software,the forging environment and deformation process of large forging case were simulated and analyzed.The influences of forging temperature,die design,forging equipment and other factors on the forging blank were discussed.The stress and strain,rule of metal flowing,forging flaw,metal lines,the final geometrical shape of finished forging,etc.during forging were analyzed.The important parameters,such as the weight of cropping,forging energy,heating times,die design,etc.in forging technology design were determined,which provide a reference for forging technology design in actual production.
Blank
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Effects on the hot forging mould cracking of typical shell were studied through analyzing the process of the typical shell,switching between product drawing and forging drawing and the description of design principles and manufacturing process.In order to avoid closed-die forging and deformstion dead areas of the shell,the problem of center location between the blank center and the die center should be solved and the effect of the flash design on the forming force should be cared during the forging design.It provides a significant reference for hot forging mould process design,forging design and die structure design of titanium alloys shell.
Blank
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By using FEM numercial simulation, the forging process of crankshaft is studied. The different structures of fash slot are mainly considered in the pre-forging process, in order to analyze the situation of the blank filling and the forging load. According to the results of numercial simulation, the structure of resistance ditch or resistance wall is reasonably added in the bridge of fash slot, which will greatly improve the filling of crankshaft's balance block, and finally optimize dimension of the blank.
Blank
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Recent years have therefore seen growing interest in gear precision forging to net-shape form of forge bevel, spur and helical gears, as an alternative to conventional manufacturing. In this paper, gear precision forging processes are simulated by using metal forming finite element code DEFORM-3D. The investigations of gear precision forging processes are conducted with perform forging and final forging processes. The processes of completely closed-die forging, moving-die forging and central divided flow forging processes are investigated for spur gears. The effect of different processes on the distribution of effective stress in the workpieces and forging loads are given. The purpose of this study is to introduce a new method, a so-called floating-relief method which applied to the forging of spur gears. It indicated that the flowing properties of the gear billet have a higher improve than that of conventional forging process. And the forging load obtained by using this new precision forging technology is decline sharply. The floating-relief method for gear precision forging is a sound process in the practical application.
Bevel gear
Spur Gear
Spur
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In the open die forging,the type of flash has great influence on the process of forging.The process of forging a same part with different type of flash was simulated by DEFORM, a large simulation software,using a finite element method.By comparing the simulation results,the conclusion how diferent type of flash will influence the filling of the mold and the forging force is achieved.
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In view of large load, the shape of large crank forgings and forging process are designed reasonably. Large crank forging process is simulated by numerical simulation software DEFORM-3D to improve the forging process and the dies, including adding upsetting step and related dies. The result shows that improved process and dies can obtain higher quality finish forgings and the load reduces to a rational level, which provides basis for crank forging process and die design.
Crank
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Aiming at the lack of filling material and low material utilization during die forging of crankshaft,the draft angle of preform die for conventional crankshaft was optimized.The finite element model was built.And then effect of different draft angles in perform die on finish-form of crankshaft was simulated.The results show that draft angle has a great effect on finish-form,which are accord with the experimental results.Finally,through the finite element analysis,optimal draft angle was found to make final forging full and meet demand of forging.
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