基于仿真与实验耦合的高强铝合金轮毂精密热锻工艺优化

Optimization of Precision Hot Forging Process for High-Strength Aluminum Alloy Wheel Hubs Based on Simulation-Experiment Coupling

摘要:

针对传统铸造轮毂易产生成形缺陷以及现代车辆对节能减排的高需求,设计了两阶段精密热锻成形工艺用于制备高强轻量化7050铝合金轮毂。通过等温热压缩试验探究7050铝合金锻材的热变形行为,基于Deform-3D软件建立预锻、终锻有限元分析模型,对热锻成形过程开展数值模拟,分析各物理场的分布特征。采用响应面法构建二阶回归模型,以降低锻造载荷、减小锻件损伤为多目标,对工件始锻温度、模锻速度及摩擦系数等关键工艺参数进行优化。优化结果表明,预锻和终锻峰值载荷分别降低了22.46%和13.26%,锻件最大损伤区域明显缩减,整体损伤水平显著降低。依据最优工艺参数进行锻造成形试验,锻件成形质量优良,综合性能均符合生产技术要求。

Abstract:

In response to the susceptibility of conventional cast wheels to forming defects and the high demand for energy conservation and emission reduction in modern vehicles, a two-stage precision hot forging process was designed to fabricate high-strength and lightweight 7050 aluminum alloy wheels. The hot deformation characteristics of 7050 aluminum alloy billets were systematically examined through isothermal hot compression tests. Finite element models for the pre-forging and final-forging operations were developed via Deform-3D software to conduct full-process numerical simulations of the wheel hub hot forging process and analyze the distribution characteristics of various physical field variables. A mathematical regression model was constructed based on the response surface methodology. Aiming at the dual objectives of reducing forging load and minimizing forging damage, key process parameters including initial forging temperature, die forging speed, and friction coefficient were optimized. The optimization outcomes demonstrated that the peak loads in the pre-forging and final-forging stages were reduced by 22.46% and 13.26%, respectively. The maximum damage zone of the forging was significantly reduced, and the overall damage level was remarkably lowered. Forging experiments were performed under the optimal process parameters, and the forgings exhibited excellent forming quality with comprehensive properties meeting industrial technical requirements.