Study On Intelligent Forging System And Quality Control Of Crankshaft

Crankshafts are the most important parts to generate and output power in engines.In our country,it is a contradiction among the increasing demand for crankshaft products,the improvement requirement on product quality,and the relatively backward forging status,so it is urgent to improve the digital and intelligent forging of crankshafts.In this paper,crankshaft forging processes,main and auxiliary equipment,characteristics and difficulties are nalyzed.An intelligent forging system for crankshaft forging production is established,and the integrated framework of intelligent control system and its components and functions are constructed.On this basis,according to analyzing typical crankshaft forging processes and die cavities by 3D numerical simulation,the intelligent sensing and detection technology of crankshaft forging was developed,key technologies of crankshaft forging quality control were studied,and crankshaft forging qualities were analyzed and evaluated.The hierarchical structure of the crankshaft forging intelligent system was studied.The results show that the crankshaft forging intelligent system can be divided into four levels,namely the crankshaft forging automatic production line and related technology and forging equipment,crankshaft forging intelligent sensing and detection system,manufacturing executing system,and expert system.Intelligent manufacturing is a systematic project,and there are many links and association between different levels.Remote diagnosis and maintenance is independent of the four levels.It is available to link to the intelligent bus control systems,MES system and expert system for enquiring,upgrading and maintenance by using of remote diagnosis and maintenance system.The control and execution modules of the crankshaft forging intelligent system include intelligent bus control system,redundant safety detection control system,remote diagnosis and maintenance system,MES manufacturing execution system and expert system.In order to achieve the coordination,high efficiency,low energy consumption,high quality and intelligent operation,it is necessary to control,coordinate and intelligently mobilize the control and executive system.The simulation of crankshaft forging forming is studied.The emphasis is on the analysis of the difficult forming area and the effect on the wear of the die.The analysis results of metal flow characteristics,stress and strain,and die wear in different stages of crankshaft forging are fed back to the control system,which can make adaptive control for the intelligent manufacturing process of crankshaft forging.The characteristics and classification of crankshaft forging parameters are studied.The results show that the forging parameters can be divided into three categories:process parameters,production state parameters and process result parameters.The process parameters have deviation in the actual production,and need to detect and correct.Production state parameters can reflect if the real-time production and equipment is in normal state,and it is also the foundation of expert system for fault diagnosis.Process result parameters reflect the quality of the products directly,which is an important part of quality traceability.The crankshaft forging intelligent sensing and detecting system includes raw material detection,temperature detection,position precision detection,die wear detection,force detection,safety inspection,size and performance detection.The application of visual recognition technology in high temperature.high pollution forging production is emphatically studied.Visual recognition is used to detect the position and shape of forgings on the press,so as to monitor the forging process and state,alarm during failure,and ensure timely intervention.It is important to realize intelligent forging production.According to analyze the mechanism of the rise of the mold temperature,characteristics of material flow and die wear,the profiling nozzle is designed,and the best ratio of water and gas is studied,which achieves good cooling and lubricating effect,and improves the service life and product quality of the mould greatly.The production and harm of oxidation skin of high temperature rod are analyzed The design pressure of the descaling device hydraulic system is 16MPa.Through the pressure and speed control of the oil cylinder,the water pressure of the descaling nozzle outlet is 4MPa.The pressure water of high pressure and small flow is sprayed onto the bar surface at 15 degree angle to remove the oxide scale,and the scavenging efficiency can reach 95%.The importance of quality tracing for forging is analyzed.The method of quality tracing for crankshaft forging is established by establishing quality archives,virtual coding technology and worksite binding technology.The microstructure and properties of typical forgings were analyzed by optical microscope and transmission electron microscope.The results showed that after forging and cooling,the microstructure and properties of the crankshafts increased slightly.