Development of a predictive simulation method for thin flash generation in flashless precision forging processes of aluminum parts using FEA and experiments
Development of a predictive simulation method for thin flash generation in flashless precision forging processes of aluminum parts using FEA and experiments
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DOI：
10.1007/s11740-018-0803-6
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发表时间：
2018-02
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影响因子：
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通讯作者：
J. Richter;M. Stonis;J. Langner;T. Blohm;B. Behrens
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文献类型：
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作者：
J. Richter;M. Stonis;J. Langner;T. Blohm;B. Behrens
本文对铝合金长扁形件精锻过程中薄飞边的产生进行了研究。其目的是推导出薄飞边生成的预测模拟方法，以提高未来的工艺和零件质量。锻造工艺通过使用具有相同体积但不同质量分布的不同预成型件而变化，同时使用相同的最终零件几何形状。分析了实验锻件薄飞边的数量和局部面积。对充型前上下模间隙附近区域的流体静压值进行了有限元模拟分析。为了进行更详细的比较，静水压力函数P中包含了单个值。P函数与实验确定的薄闪高度之间的比较表明，P函数的高压力值以及高梯度表明薄闪产生较少。因此，该方法允许定性预测薄闪光的产生。它可以提供两种信息。第一：通过使用单个预成型件来预测最终部件中可能发生薄飞边的具体位置。第二：根据不同的预成型件几何形状，可能发生薄飞边的特定最终部件区域的定性预测。该方法将减少耗时的锻造试验的必要性，并可缩短未来的预成形设计过程。
In this paper, the investigation of thin flash generation in precision forging process of an aluminum long flat part is described. The aim was to derive a predictive simulation method for thin flash generation in order to increase both process and part quality in the future. The forging processes were varied by use of different preforms with equal volumes but different mass distributions while using the same final part geometry. The experimentally forged parts were analyzed concerning the amount and part area of the generated thin flash. The conducted FE simulations were analyzed concerning the hydrostatic pressure valuespin the part areas near to the tool gap between upper and lower die immediately before form-filling. For a more detailed comparison, singlepvalues were included to hydrostatic pressure functionsP. The comparison between thePfunctions and the experimentally determined thin flash height shows, that high pressure values as well as high gradients of thePfunctions indicate less thin flash generation. The method therefore allows a qualitative prediction of thin flash generation. It can provide two kind of information. First: The prediction of the specific locations where thin flash is likely to occur in one final part by use of one single preform. Second: The qualitative prediction of the specific final part areas were thin flash is likely to occur depending on different preform geometries. This method will decreases the necessity of time-consuming forging trials and can shorten the preform designing process in the future.