The Research On The Technology Of Whole Roll Forging Making Billets Of Connecting Rod Of Large And Different Sections Based On Numerial Simulation

Large forging is an important basic part for the national great technological equipment and momentous construction projects, its manufacturing capacity an important symbol to measure of overall strength of a heavy equipment manufacturing industry. In the "11th Five-Year" national technological supported program, Science and Technology Department has set up a key project, named "key technology and equipment development of large forgings manufacture". The project focuses on solving a number of key technologies and bottleneck problems, which consist in large forging manufacturing process key technology and testing technology in our country heavy equipment manufacturing. Currently, comparing the manufacturing ability and technique level of our country large forgings and large forging equipment with that of abroad, there is still a wide gap. Some large, critical forgings still need to import, controlled by others.This topic is one of the contents of the key technology tackle key problem program, which is mounted for "10 billion long march" by Science and Technology Commission of Chongqing Municipality in 2009. Under the circumstance of relocating equipment of the project partners—Chongqing Changzheng Heavy Industry Co., Ltd and aiming at the production of large Marine middle-speed diesel connecting rod, and on the basis of the existing production technology, we optimize forging blank and put forward the whole roll Forging,molding process scheme. Roll forging process is characterized by a continuous local plastic deformation. Taking full advantage of the deformation characteristics of roll forging, making forging blank by roll forging, and adopt roll forging process program can greatly reduce the tonnage of forging equipment. Being dead against specific parts and designing reasonable roll forging project can realize local forging, further reduce energy consumption of equipment.A large Marine link is an important movement of middle-speed diesel, belongs to the category of large forgings. At present, by the limitations of forging equipment in our country, most manufacturers use split forging and machining to connect. And there is no mature forging process forging connecting rod as a whole. The research of reasonable blocking technology of such kinds of parts is wondrously important to optimize blank, improve material utilization efficiency and reduce the machining and reduces power requirements, etc. Through theoretical analysis and the detailed process calculation, die forging blank which is roll forging parts is calculated. By using the numerical software, forging process after blocking and each step of roll is simulation and repeated verification, with the reasonable technical parameters. And optimize blank by using the simulation result. According to the optimized forging blank, frame the roll forging process of making blank after analysis and calculation of roll forging process. Design the four roll forging die, combining the research project experience and considering some factors of roll forging die design. Then,sculpt roll forging die with parameter and simulation the four steps roll forging process by finite element analysis software Deform 3D.Analyze the process parameters of every four pass of roll forging, such as material flow, equivalent strain, roll forging moment etc, effect on the figuration. Using simulation result, improve the roll forging process project. Put up a theoretical analysis of roll forging flash, matching of each path, and modify the roll forging process, roll forging dies. Then, the scheme is numerically simulated by using the modified program. For the theoretical reasons of the problems in the roll forging, as coefficient of friction, instability, variable cross-section roll forging, material flow etc, is studied and carried on various data numerical simulationThe study of this topic, for large forgings Roll Forging process of development, has practical instructional significance, and play a role of technical support of the project partners—Chongqing Changzheng Heavy Industry Co., Ltd.