钢活塞锻造过程的数值模拟分析

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1、上海交通大学硕士学位论文钢活塞锻造过程的数值模拟分析姓名：汪磊申请学位级别：硕士专业：材料工程指导教师：陈军;王以华20081101上海交通大学硕士学位论文摘要预成形的影响，优化了模具型腔设计，解决了成形过程中产生的折叠和充不满缺陷，并将成形工步减少到两个，同时有利于提高了模具使用寿命。新产品开发达到一次试制成功，使试制费用降低一半。(2)选用多种规格的坯料进行模拟，研究了坯料尺寸对锻件成形过程的影响，确定了所用原材料的直径和长度，将原材料利用率从国外平均水平83.10%提高到85.15%，节约能源，提高了经济效益。关键词：锻钢活塞

2、，预成形，数值模拟II上海交通大学硕士学位论文摘要RESEARCHONFESIMULATIONOFFORGINGPROCESSOFSTEELPISTONABSTRACTAsoneofthemainengineparts,pistonplaysanimportantroleintheperformanceparametersofthewholeengine.Enginehasbeenincontinuousdevelopment.Andthisisbasedonthedevelopmentofpropertiesandlife-cir

3、cleofitsprimarycomponents.Foryears,traditionalaluminumalloyPistonhasbeenbecomingharderandhardertomeetthecontinuouslystrengthenedrequirementsandsevereemissionregulations(EuroIII,EuroIV,EuroV).Itbecomesessentialtodesignnewtypepistonwhenaluminumalloypistoncan’tadapttheeng

4、ine’sreliabilityanymore,especiallywhenpeakpressureisupto20MPaandmore.Asakeypart,thedemandsofthesteelpistonareupperonthesurfacequalityandinteriorstructureanddimension.Ontheotherhand,theenginewithasteelpistonhasbeingwidelyusedinindustry，agriculture,trafficandnationaldefe

5、nsefields.Thedemandofthesteelpistonislarge.139piston,thesteelpistonforgingisresearchedinthisthesis.Wewillsimulatetheforgingprocessindifferenttechnicsparameterswiththefiniteelementanalysissoftware,QForm.Theeffectisresearchedtosurfacequalityanddimensionandlifeofmouldduri

6、ngthesimulation.Theforgingtechnicsparametersareoptimizedaccordingtotheresultofsimulation.Forthis,theempolderingcycleisshortened.Thepistonisproducedinbatchtobringincrementalbenefit.Thecontentandconclusionarewrittenasfollows.(1)Weresearchthathowthecavityofthepreforgingmo

7、uldeffectstheforgingprocess.Wesolvethedisfigurementsuchaslap,underfillwiththeoptimizedforgingtechnicsparameters,improvingthemouldlife.Thenumberofformingstepsislessenedtotwo.Thecostislessenedwiththeonlytrial-produce.(2)Weresearchthathowthedimensionofbilleteffectstheforg

8、ingprocess.Weascertainareasonablesizebillettoproduceeconomically.Theutilizingrateofmaterialisimprovedfrom83.10%to85.1