Simulation-enabled study of folding defect formation and avoidance in axisymmetrical flanged components
Simulation-enabled study of folding defect formation and avoidance in axisymmetrical flanged components
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DOI：
10.1016/j.jmatprotec.2009.02.005
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发表时间：
2009-06
影响因子：
6.3
通讯作者：
W. Chan;M. Fu;Jian Lu;L. Chan
中科院分区：
文献类型：
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作者：
W. Chan;M. Fu;Jian Lu;L. Chan
在金属成型工业中，产品质量、产品成本和上市时间是三个最重要的问题。在这些问题中，产品质量是最关键的问题。缺陷是成形过程中的关键质量问题之一。不合理的材料流动和不合理的应力和温度分布会导致坯料和模具的缺陷形成。在轴对称法兰件锻造过程中，折边是一种常见的流动缺陷。本文采用有限元模拟方法，系统地研究了轴对称法兰件锻造过程中褶皱缺陷的形成及避免机理。在模拟材料流动行为的基础上，揭示了缺陷的形成机理，并提出了通过模具几何形状的动态变化来避免缺陷的机理。该机构是通过在模具中实施滑动插入结构来实现的，以控制材料流动并进一步避免折叠缺陷的形成。此外，还研究了初始插片位置、摩擦系数和动模弹簧刚度对材料流动行为和变形载荷的影响。基于所建立的有限元模型的仿真结果，提出了一种通过CAE仿真预测和避免折叠缺陷的系统设计框架。通过一个工业案例研究，最后验证了研究结果和提出的缺陷避免机制。
In metal forming industries, product quality, product cost and time-to-market are three overriding issues. Among these issues, product quality is the most critical one. Defect is one of the key quality issues in forming processes. Defect formation can be caused by irrational material flow and unreasonable stress and temperature distribution in billet and tooling. In forging of axisymmetrical flanged parts, folding is a common flow-induced defect. In this study, the mechanisms of folding defect formation and avoidance in forging of axisymmetrical flanged parts are systematically studied via FEM simulation. Based on the simulated material flow behavior, the defect formation mechanism is revealed and an avoidance mechanism through the dynamic change of tooling geometry is proposed. The mechanism is realized by implementation of a sliding insert in die structure to control material flow and further to avoid the formation of folding defect. In addition, the effects of the initial insert position, frictional factor and the spring stiffness of the moving die module on the material flow behavior and deformation load are investigated. Based on the simulation results of the developed FEM models, a systematic design framework to predict and avoid folding defect via CAE simulation is proposed. Through an industrial case study, the findings and the proposed defect avoidance mechanism are finally verified.