Rod Forgeable Piece Numerical Simulation And Optimization Of Stock

Mobile engine rod is a kind of important part which multitudinous production, it is important that optimize forgeable piece stock, increase stock utilization and decrease costs. This paper is base on the research on rod production technology, through the optimization of mobile engine 462 rod blocker and roll forming die of JiangDong factory, it not only decrease the raw materials waste but also find out the rod forming technology, especially, we find out the scientific way of simulation of roll forging.Base on the analysis and summary of old process, the new stock has been given out. We modified the model of blocker, and it has been simulated by commercial software DEFORM-3D. The influence of forming process have been analyzed in dummying and finish forging process such as stress, strain, maximum loading, shaped results. Several experiments have been done, and the corrective method have been given out through the analyze experiments'results, check the die's finish size, and adjust the forging stock size. The pucker and underfill defects have been resolved. In final, we get the optimized forging stock size.The rod's four times roll forging die have been designed according the confirmed forging stock, and we built the parameterize model of roll forging die. The connection between to curved surface is complicated; the difficult point is chamfer angle hart to build from one curved surface to another curved surface because section has change with no discipline. So, the Uigraphics has been applied in the process of building model, and the key parts have been ensured through the parameterize set up in the process. We can modify the key parameter of mold through the simulation results. The roll forging forming of rod has been simulated by commercial software DEFORM-3D. The contactions at the simulation beginning, entrances and restrictions have been probed. The minimum diameter has been chosen out for saving in material and raise stock utilization with no bend happed in the roll forging process. The influence of forming process have been analyzed in every process such as stress, strain, maximum loading, shaped results, value of speed gain. The key factors of roll forging when we design have been given out and the solutions also have been given out in contactions, entrances, bending and die clearance of roll forging.The roll forging die, dummying,final forging die have been proved through experiments, and the reasons of pucker defect have been analyzed through the experiments results and numerical simulation results. We not only increase the stock utilization from 60% to 71%, but also save material cost 2 million approximately in every year. This achievement can be utilized others work in rod production industry in China. The more important thing is the successful experiences in roll forging simulation will have active contribution to application of roll forging.