Numerical Simulation Analysis Of Aluminum Alloy Connecting Rod Rough With Multi-Wedge Cross Wedge Rolling

The connecting rod is one of the most important parts in the engine, which plays a key role in the normal operation of the engine. But because of the complicated shape of the connecting parts, its quality is closely related to the distribution of quality of billet, continuity and distribution of metal fiber flow line. It is difficult to accurately control quality distribution of blank, and guarantee the continuity and uniform distribution of the metal fiber flow line for the connecting rod which making by the traditional process. The productivity is not high, and the degree of mechanization is low. The quality and output of the connecting rod are seriously affected by all of them. However, the billet, which be made by cross wedge rolling, in improving the blank shape dimension precision, surface quality, mechanical properties and productivity has more obvious advantages. It has important guiding significance for pursuing the production of connecting rod with high quality, high efficiency and section material.In this paper, The finite element numerical simulation of the aluminum alloy axial parts was carried out by using rigid plastic finite element theory in cross wedge rolling. And the results are compared with the real experiment results. The results show that the finite element simulation results and experimental results are basically the same. It shows that the numerical simulation method is accurate and reliable by using rigid plastic finite element theory. On the basis of it, high strength aluminum alloy was selected as raw materials for production in this program, and multi-wedge cross wedge rolling was applied for forming an engine connecting rod rough by numerical simulation, to explore the deformation mechanism and defect generation mechanism and its influencing factors. It is benifit for subsequent forging connecting rod to provide quality assurance and provide the reference for the production of aluminum alloy connecting rod. The main conclusions are as follows:(1)Workpiece of metal flow research shows that:tthe metal flow is slow in the center of workpiece, fast in the surface; The grid of central region of middle thin rod is severely compressed, stretched and twisted. So the middle section of the thin rod section is easy to produce necking and the heart defect; the end of the thin rod is easy to produce necking defect.(2)The study of stress and strain shows that:Intermediate thin rod have large deformation. The core stress strain, the lattice distortion and the density of dislocation in the the middle section of intermediate thin rod is larger. So it is easy to produce the heart defects such as loose, shrinkage and so on. It is beneficial to reduce the heart defects by appropriately increasing the rolling speed, the main side wedge forming angle, or the appropriate reduction of the spreading angle of the medial wedge.(3)The main factors influencing the formation of the reactor are the velocity and the displacement direction of the metal flow, which are related to the rolling speed of the roller, the distribution coefficient of the section contraction, the inclined plane of the forming wedge (forming angle). By choosing appropriate rolling speed, appropriate to reduce the section shrinkage coefficient of distribution, main side wedge and medial wedge forming angle is helpful to reduce the rolling big end stacker.