GH4169合金叶片挤杆工序模具磨损及寿命的数值模拟分析

挤杆工序是GH4169合金叶片热成形的首道工序,作为制坯工序,其不但要保证精确的尺寸形状,还要确保工件组织达到工艺要求。模具的工况严重地影响了工件的内在质量。基于Archard磨损理论,以凹模为研究对象,采用Deform-2D有限元软件对其磨损过程进行数值模拟,通过分析工件的模具温度、模具硬度、挤杆速度、摩擦系数、凹模圆角半径等工艺与模具参数对凹模磨损的影响,获得了相关因素对凹模磨损的影响规律;采用磨损量累计,按工艺要求以最大磨损量0.2 mm对凹模寿命进行预测。结果表明:采用有限元模拟挤杆过程,分析模具受力和磨损情况及其对工件质量的影响,进而优化模具设计和工艺参数,在提高工件质量的同时,延长了模具寿命,降低了生产成本。

Numerical simulation analysis on wear and life of mold in bar extrusion process for GH4169 alloy blade

Rod extrusion process is the first process during the hot forming of GH4169 alloy blade. As a billet-making process,it not only ensures the accurate size and shape,but also ensures that the microstructure of workpiece meets the process requirements. However,the working condition of mold seriously affects the internal quality of workpiece. Therefore,based on the Archard wear theory,taking the lower mold as the research object,its wear process was simulated by finite element software Deform-2D,and the influences of process and mold parameters such as workpiece temperatures,mold hardness,speed of bar extrusion,friction coefficient and fillet radius of lower mold for workpiece on the lower mold wear were analyzed to obtain the influence laws of relevant factors on the lower mold wear. Furthermore,the wear amount was accumulated,and the mold life was predicted with the maximum wear amount of 0. 2 mm according to the process requirements. The results show that the finite element method is used to simulate the bar extrusion process so as to analyze the force and wear of mold and the influences on the quality of workpiece and optimize the mold design and process parameters. While improving the quality of workpiece,the mold life is extended and the production cost is reduced.