Simulation algorithm for the assessment and modification of multi-directional forging processes and tool geometries
Simulation algorithm for the assessment and modification of multi-directional forging processes and tool geometries
复制标题
用于评估和修改多向锻造工艺和工具几何形状的仿真算法
DOI：
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发表时间：
2012
期刊：
影响因子：
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通讯作者：
M. Stonis
中科院分区：
文献类型：
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作者：
B. Behrens;R. Nickel;M. Stonis
在汽车工业中，铝合金零件的使用越来越频繁。在生产铝长扁平件的锻造操作过程中，可能会出现折叠等缺陷。特别值得关注的是内部折叠，它仅在纤维取向中明显，并且对锻造零件的动态机械性能产生负面影响。在锻造中，成形操作可以从一个方向（单向）或从多个方向（多向）实现。本文描述了多向锻造的边界条件。对于给定的工具几何形状，多向锻造允许实现无折叠锻件，这已被证明是单向操作不可能实现的。基于有限元分析模拟的新开发方法有助于设计成形工艺并确定适当的工具几何形状。一种新算法集成了内部褶皱的计算机辅助识别。对于给定的工艺和工具几何形状，调整具有内部折叠的区域，直到模拟显示没有折叠形成。结果表明，通过使用该模型，可以对锻造工具和成形过程进行可靠的评估和校正，从而实现无折叠成形。
In automotive industry, parts made of aluminum alloys are used with increasing frequency. During forging operations for the production of aluminum long flat pieces, defects like folds can appear. Especially internal folds are of interest, which are only evident in the fiber orientation and have a negative effect on the dynamic mechanical properties of the forged part. In forging, the forming operation can be realized either from one direction (uni-directional) or from several directions (multi-directional). The boundary conditions for multi-directional forging are described in this article. For a given tool geometry, multi-directional forging permits the realization of fold-free forgings, which has been shown to be not possible with uni-directional operations. A newly developed method based on finite-elements-analysis simulation helps with the design of the forming process and the determination of the appropriate tool geometry. A new algorithm integrates the computer-aided identification of internal folds. For a given process and tool geometry, the area with internal folds is adjusted, until the simulation shows no fold formation. It is shown, that by using this model, a dependable assessment and correction of forging tools and forming process and thus the realization of a fold-free forming are possible.