Design Of Forging Process And Dies And The Numerical Simulation Of Typical Forgings For Construction Machinery

Construction machinery industry started relatively late in China. After decades of rapid development, China’s construction machinery industry has already been able to meet the demand of both domestic and international market, which, to a large extent, promotes the development of national economy. However, with the development of economic globalization, China’s construction machinery industry still has shortcomings in comparison with foreign countries.Tread shoes are the key component of track driving device. The quality requirements for tread shoes are usually high as they contact with ground directly and have complex shapes. Traditional tread shoes were produced by casting process, which usually results in high frequency of defects and low product properties. Thus, a new forming method needs to be developed. As tread shoes hold a large proportion in track driving device, the increase of the weight of tread shoes will lead to more engine power, more fuel consumption and the decrease of service life. So, the structural optimization of tread shoes is of great significance to improving the comprehensive properties of the complete machine and saving energy."日" shape forgings are widely used in practical production, but they are difficult to form because of their complex shape. The existing forging process is a single channel time forging process, which tends to lead to forging defects such as inaccurate positioning and severe folding. These defects will reduce the mechanical properties and shorten the service life of the forgings. Thus, developing a new forming technique and die has an important practical significance in solving problems in practical forging production.In this paper, the forging process of the tread shoe of216pitch was analyzed, the billet volume was calculated, the equipment tonnage was determined and the finishing impression was designed. Then, a FE model for the forging process of tread shoe was established by DEFORM-3D. By numerical simulation, the forging process of tread shoe and the flowing law of metal were analyzed, the forging scheme was optimized and a reasonable pre-block shape was obtained. Finally, the forging process of tread shoe products and die structure were determined.Based on the reasonable pro-block shape and die structure, the forging process of "日" shape forging was simulated by DEFORM-3D. By metal flowing analysis, stress field analysis, strain field analysis, temperature analysis and forging force analysis, the forming law of the "日" shape forgings and the cause of folding defects were studied, which provides guidance for subsequent process and die design.