Simulation And Technology Design For Precision Forging Of Alternator Pole

Alternate pole, which has complex shape and strict limit in its size and quality, is the key part in the automobile generator, so it is difficult to produce. In this paper, based on the study of the overseas and domestic actuality and development for the alternate pole in the manufacture field at present, the forming process of alternate pole is analyzed and the closed die forging process is introduced. Characteristics of closed die forging process are introduced. The major factors that affect the sizes of the forged part are researched.Based on the theories of finite element method, the calculation model of the forging processes for the pole is established. Based on general finite element software ABAQUS/EXLICIT, 3D rigid visco-plastic FEM is used to simulate the precision forging process; the laws of material flow and equivalent plastic strain distribution are revealed.The process parameters and mould structure for precision alternator pole forging are researched through FEM simulation. Based on the FEM simulation, the proper diameter of the blank is confirmed; the mould structure is optimized and the type of press machine is chosen. Based on the FEM simulation, the effects of the velocity of press machine and the friction between blank and mould on the forming load are researched. The simulation adopts the adaptive meshing technique and the pure Lagrangian analysis. The simulation results prove that the adaptive meshing is particularly effective for simulations of metal-forming processes such as forging.Based on the closed die forging process and the FEM simulation for the pole, the mould structure for precision alternator pole forging is designed. The requirements of the die design are advanced. A die set of closed die forging for the poles is introduced; Guiding device and ejector are introduced; Material selection and heat treatment of main elements are described.A CAD system of the process design for pole forging is built on the UG platform by utilizing UG redevelopment tools: UG/Open API and Visual C++6.0. This paper introduces the methods of the user interface development. And it stress the methods of setting user environment variables, user interface menu and toolbarsdevelopment, several examples are given in the paper. The methods of secondary development for UG based on parameterized technology are introduced. The interface technology in secondary development is described. According the requirements, the function of the system is designed. In the field of designing pole forging process, the CAD system improves the efficiency and shortens the cycle time.Based on the results of FEM simulation, the process parameters and mould structure for precision alternator pole forging are optimized. Experiment of precision alternator pole forging has been made, the qualified alternator pole has been formed, and FEM simulation results are verified by the experiment.