20Mn5超大型空心钢锭在上平下V砧翻转芯轴拔长过程中采用普通V砧进行顺序翻转,锻件变形极不均匀且存在密集型疏松缺陷。通过DEFORM-3D数值模拟和理论推导,定量给出发散角和理论翻转角度与V砧角度和压下率的关系,提出不同压下率下的普通V砧翻转新工艺。数值模拟和物理试验结果表明,单砧压下时大圆角V砧和凸型V砧两种新型V砧的变形均匀性和压实效果均要优于普通V砧。翻转拔长模拟结果表明,不同压下率下凸型V砧、大圆角V砧和普通V砧翻转新工艺的变形均匀性和压实效果均要优于普通V砧顺序翻转,其中大圆角V砧翻转新工艺的变形均匀性最优,凸型V砧翻转新工艺的压实效果最优。研究结果可为国产大型筒体锻件空心钢锭锻造工艺规范的制定提供重要理论参考。
Sequenced rotation with ordinary V-shaped anvil is used in the upper flat and lower V-shaped anvils mandrel drawing process of 20Mn5 super-heavy hollow steel ingot, but the forging deforms unevenly and contains intensive porosities. By numerical simulation using DEFORM-3D and theoretical derivation, the relationship between divergence angle, theoretical rotation angle, V-shaped anvil angle and reduction rate is given quantificationally, and the new rotation processes with ordinary V-shaped anvil at different reduction rates are proposed. Numerical simulation and physical experiment results show that the deformation uniformity and compaction effect of big fillet V-shaped anvil and convex V-shaped anvil is better than that of ordinary V-shaped anvil for single press. Simulation results of rotatory drawing show the deformation uniformity and compaction effect of new rotation processes with convex V-shaped anvil, big fillet V-shaped anvil and ordinary V-shaped anvil is better than that of sequenced rotation with ordinary V-shaped anvil at different reduction rates, while the deformation uniformity of the new rotation process with big fillet V-shaped anvil is best and the compaction effect of the new rotation process with convex V-shaped anvil is best. The results can provide important theoretical reference for establishment of hollow steel ingot forging process specification of national heavy cylinder forgings.
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