Study On The TR Method Forging Process Of Heavy Crankshaft And TR Forging Device Structural Strength Analysis

Heave crankshaft is the key component of diesel engine. Crankshaft work situation is extremely complex, and it's manufacturing quality impacts diesel engine performance and reliability. With shipbuilding, petroleum, power generation, diesel locomotives develop rapidly these years, the market need large numbers of high-quality, full-sized fibers diesel engine crankshafts. The current domestic situation is still in short supply, relies on import expensive from abroad.Crankshaft converts gas pressure from side rod into torque, which acts as the driving force and output. The crankshaft's work situation is extremely complex, enduring a cyclical change in reverse, bending, compression and tensile stress, and other complex stress state. Therefore, it requested a crankshaft has good strength and stiffness; wearable fatigue resistance, impact resistance; balance of high size, shape, location accuracy, and low surface roughness. Crankshaft requires internal and surface defects as few as possible, a reasonable distribution of fibers, and these demands and closely related materials and processing technology.At present heavy crankshaft forging process consists of free forging and upsetting. All-fibred upsetting process has greatly improved the crankshaft fatigue, and improves the utilization of metal machining efficiency, which is superior to free forging. All-fibred crankshaft upsetting Forming Technology RR method and TR method have been widely used abroad, but in the process there are some inherent problems to be resolved, such as the existence of non-metal flow basis for the rational design of the mold key parameters. At present law at home and abroad RR method crankshaft upsetting forging process and numerical simulation has studied a lot, and substantial progress was made. But TR method which is superior to RR method lack in-depth study, and only confined to forming process analysis.In this paper, the CSR Locomotive Company 3,600 MN hydraulic machine equipped with the TR forging device is subject investigated, the TR forging device was researched from mechanical and kinematics, the characteristics of such devices and work rules was analyzed. Then combine production practice, focusing on large-scale crankshaft flange, crank forming process was studied, forecasting forming force, forming effect, forming defects and defects. A series of effective measures to avoid defects in accordance with the mechanism were put forward and analyzed test. L27/38 crankshaft folding defects mould key parameter optimization was researched, and through comparative analysis reasonable Die key parameters were obtained. Based on the analysis of the 6G32 crankshaft forging simulation result, the TR devices structural strength was analyzed, and the stress and strain status at the end of the forming process was gained. According to the structural strength analysis result, explained the damage reason of TR forging device, and gives recommendations and structural optimization.Through this research in the process of forming crankshaft TR method, finite element theory, numerical simulation technology and die with CAD technology were combined, to shorten the product development cycle, the die life and lower the costs of purpose. The results of research by the TR crankshaft forming mold select key parameters, defect prevention provides a theoretical and practical basis, and could be directly used for the production of guidance.