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采用EN AB-71100铝合金铸造预成型坯进行汽车连杆模锻的新技术。

The New Technology of Die Forging of Automotive Connecting Rods from EN AB-71100 Aluminium Alloy Cast Preforms.

作者信息

Dziubinska Anna

机构信息

Metal Forming and Casting Department, Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, Pl. Politechniki 1, 00-661 Warsaw, Poland.

出版信息

Materials (Basel). 2023 Apr 3;16(7):2856. doi: 10.3390/ma16072856.

DOI:10.3390/ma16072856
PMID:37049150
原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC10095791/
Abstract

This article presents a new technology for forming automotive connecting rod forgings by means of die forging from cast performs from EN AB-71100 (EN AB-AlZn10Si8Mg) aluminum alloy. A premise was made that the production process would be carried out on forging presses. The process of forming connecting rod forgings was analyzed considering different deformation rates related to the type of machine used: a crank press and a screw press. The billet in the form of in-house designed, shaped preforms cast into sand molds with two variants of geometry was used in the process. The numerical analysis of the new process was carried out on the basis of the finite element method using Deform 3D, the simulation software for metal forming. The simulations were conducted in the spatial deformation conditions, considering the full thermomechanical analysis. Based on the simulations, certain important findings concerning the novel process were acquired, including the distribution of stress, deformation, temperatures, cracking criterion and energy parameters. The results of numerical tests confirmed the possibility of producing defect-free forgings of connecting rods from EN AB-71100 aluminum alloy on forging presses by means of the proposed technology. The proposed process of forging using crank and screw presses was verified in the course of tests conducted in industrial conditions. The properly formed connecting rod forgings were subjected to quality tests in terms of their structure and mechanical properties.

摘要

本文介绍了一种利用模锻工艺，从EN AB - 71100（EN AB - AlZn10Si8Mg）铝合金铸造坯料制造汽车连杆锻件的新技术。前提是生产过程将在锻造压力机上进行。考虑到与所使用机器类型（曲柄压力机和螺旋压力机）相关的不同变形速率，对连杆锻件的成形过程进行了分析。该过程使用了内部设计、形状的预成型坯，以两种几何形状变体铸造成砂模。基于有限元方法，使用金属成形模拟软件Deform 3D对新工艺进行了数值分析。模拟是在空间变形条件下进行的，考虑了完整的热机械分析。基于模拟，获得了关于新工艺的一些重要发现，包括应力、变形、温度、开裂准则和能量参数的分布。数值测试结果证实了通过所提出的技术在锻造压力机上用EN AB - 71100铝合金生产无缺陷连杆锻件的可能性。在工业条件下进行的测试过程中，对使用曲柄压力机和螺旋压力机的锻造工艺进行了验证。对正确成形的连杆锻件进行了结构和力学性能方面的质量测试。

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