Development And Application Of A Upset Forging Test Machine For Physical Simulation Of Continuous Grain Flow Forming Of Large Crankshaft

The upset forging technology, which is used for heavy crankshafts, marine stern shaft, fan shaft and some other large forgings is difficult to achieve and the cost is very high. The quality problem of the forgings is often caused by the unreasonable forming process and sometimes the forgings must be discarded. Hence, simulative engineer test should be done before manufacturing. The upset forging test machine for physical simulation of continuous grain flow forming of large crankshaft is used in providing the analog engineer test equipment in proportion, verifying the forming process and the mold design.The upset forging test machine for physical simulation of continuous grain flow forming of large crankshaft is studied in this thesis and the following work has been completed:1. The mechanical system of the device and the scheme are proposed, according to the simulative engineer test.2. The scheme of open measurement and control system based on the industrial computer and NI-7344 motion controller is proposed, according to the test requirement, machine's credibility and manufacturing cost demand. The hardware of the measurement and control system is designed.3. The software of measurement and control system is developed based on the software platform. The system includes the motion control module, data acquire module. Human-computer interface is programmed.4. The device is tested according to the reasonable means. The result manifests that it can work normally. The mechanical precision and data acquirement are all meet the requirement so that the device has been proved feasibility and reliability.5. The machine is used in the simulative test of the 6G32 large crankshaft of continuous grain flow. The prospective target has been achieved according to the device test.