Research On Numerical Simulation Of Forming Process Of Aluminum Alloy Engine Cylinder Liners

Forming process of dry-type of aluminum alloy cylinder liner for 4JB1 diesel engine is the object of study. Extrusion forming process and spinning forming process are analyzed by finite element method. Numerical simulation under different forming processes and different technological parameters is achieved respectively, and the impact of different technological parameters on alloy flow velocity, von mises stress, plastic strain, extrusion force and spinning force is researched, and appropriate parameters are also acquired. The results show that, extrusion speed of 2mm/s and friction coefficient of 0.05 are appropriate parameters in extrusion, and feed ratio of 2mm/r at first pass and 1mm/r at second pass are appropriate parameters in spinning.According to the parameters acquired by numerical simulation, the forming process experiment of aluminum alloy cylinder liners is studied, and the aluminum alloy cylinder liners are produced successfully, whose shape and size are meet requirements. Through the material tensile test, the mechanical properties of aluminum alloy cylinder liners are also meet requirements.The forming process analysis software of aluminum alloy cylinder liners is used in numerical simulation, which is based on finite element method software ANSYS/LS-DYNA, ANSYS Parametric Design Language (APDL) and Visual Basic 6.0. The software which has pre processor, solver and post processor, can do numerical simulation of forming process of aluminum alloy cylinder liner easily and conveniently, and it is conducive to applying the numerical simulation technology in industrial production. The experimental results show that this software is useful and feasible.