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ProKomb - Process combination of cross wedge rolling with multi-directional forming

ProKomb - 楔横轧与多向成形的工艺组合

基本信息

批准号：
239066313
负责人：
Dr.-Ing. Malte Stonis
金额：
--
依托单位：
Institut für Umformtechnik und Umformmaschinen (IFUM)
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2014
资助国家：
德国
起止时间：
2013-12-31 至 2015-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/239066313?language=en
关键词：
ProKomb Process combination cross wedge

项目摘要

High-duty complicated long parts made of steel are usually forged with flash in several stages. The potential of flashless forging of these parts to increase the resource efficiency in production has been demonstrated in recently completed research projects using crankshafts as example. A defect-free, four-stage sequence has been developed for a two-cylinder crankshaft with secondary form elements pin and flange. The stages are cross-wedge rolling, lateral extrusion, multi-directional forging and precision forging. The multi-directional forging has been identified as an essential step in order to realize an offset between pin bearings and main bearings in a flashless forging operation. The shortening of the process steps to three steps without the lateral extrusion partially caused a formation of folds and flash. The causes of these defects have not been identified, yet. The absence of knowledge about the causes prevents a reliable design of the appropriate processes. To identify the dependency between the geometry of the cross wedge rolling and the multi-directional forging concerning the development of folds and flash is therefore essential in order to forge complicated forgings flashlessly. This is necessary for a shortened forging sequence.In order to forge complicated forgings flashlessly in a shortened process chain, the aim of the project is to investigate the relationship between cross-wedge rolling and multi-directional forging. The main focus lies on the geometrical aspects. A universal mathematical model shall facilitate the design of the geometry of cross-wedge rolling preforms and the forming elements of the multi-directional forging tool. The boundary conditions of the model shall be determined using finite element simulations of the forming processes and shall be verified in forging trials. Shafts without an offset of the main bearing and crankshafts (with the offset) are taken into account to be able to transfer the application to a wider variety of complicated long parts.

大型复杂长形钢件多采用飞边分段锻造。这些零件的无飞边锻造在提高生产资源效率方面的潜力已在最近完成的研究项目中以曲轴为例得到证明。针对具有二次成形元件销和凸缘的双缸曲轴，开发了一种无缺陷的四阶段顺序。这些阶段是楔横轧、侧向挤压、多向锻造和精密锻造。多向锻造是实现销轴承与主轴承间偏心的必要步骤。将工艺步骤缩短为三个步骤而不进行横向挤出部分地导致了褶皱和飞边的形成。这些缺陷的原因尚未确定。由于缺乏对原因的了解，无法可靠地设计适当的流程。因此，为了无飞边地锻造复杂锻件，识别楔横轧和多向锻造的几何形状之间关于褶皱和飞边发展的依赖性是至关重要的。为了在缩短的工艺链中实现复杂锻件的无飞边锻造，本项目的目的是研究楔横轧与多向锻造之间的关系。主要的焦点在于几何方面。通用的数学模型将有助于设计楔横轧预成形件的几何形状和多向锻造工具的成形元件。模型的边界条件应使用成形过程的有限元模拟来确定，并应在锻造试验中进行验证。考虑了没有主轴承偏移的轴和曲轴（有偏移），以便能够将应用转移到更广泛的复杂长零件。