NC Machining Of Crankshaft Die And Numerical Simulation Of Die Forging Process

The crankshaft of automobile is the key piece in engine, the situation of receiving pressure is complicated and working condition is poor. It is usually formed difficultly in die forging and manufacture of die is also difficult, so that the crankshaft forming process attracted more attention. In recent years, the production of crankshaft increases year after year along with increase of automobile output. The requirements are repeatedly stated about heavy load, high speed and high reliability of crankshaft. So it is very important to improve processing technology of crankshaft, the application of CAD / CAE / CAM has played an important role in promoting the development of the crankshaft forging process.This paper briefly introduces the present conditions to die forging forming of crankshaft in the research and manufacture of domestic and abroad. Choosing a crankshaft has three cylinder sleeve that every one is 120o distributional and has six balance weight as a object of study, introduces the application of CAD/ CAM /CAE technology in optimization of die forging process for crankshaft. First of all, the three-dimensional model of pre-forging and finish-forging crankshaft and die can be set up by the use of the CAD system in UG. Secondly, by using the CAM system in UG, NC machining to die, in this stage, completed the manufacturing craft analysis to the die, ultimately the appropriate manufacturing parameters and cutting strategies were choose. Use UG / CAM NC programming modules, optimized the manufacturing line, tool path, cutting mode parameters and the highly precise and highly effective NC procedures. Finally, simulate the forming processes of crankshaft forge piece by using the finite element numerical simulation soft—DEFORM-3D. Analysis the influence on the metal flow, mould filling, stress and strain distribution of forging part, temperature distribution of forging part and die and others via the simulation. By analyzing the simulation, we optimize the size of blank and wad, which realize the target of optimizing the process parameters and getting rid of the forming defects.In this paper, the precision die forging of crankshaft, finite element theory, numerical simulation, and CAD/ CAM technology of mould are combined. The research results achieve the following purpose: shortening the cycle for product development, reducing the material cost, and improving the die life, etc.