Axle Box Molding Numerical Simulation And Mold Design

Magnesium alloys has been widely used in new industrial environments and modern transportation equipment because of their advantages such as light weight,high strength,and good damping.However,magnesium alloys are also accompanied by shortcomings such as narrow molding temperature range and sensitive strain rate,which can only produce parts with simple processing structures.Superplastic forming can perform the one-time molding of complex parts.This provides a feasible method for shortening the production cycle,reducing the traditional machining,and saving the cost.In this paper,the superplastic forging forming process is proposed for the complex axle box of vehicle components.AZ80M magnesium alloy of the research group design compon-ent is selected as the axle box material.The molding process and service state of the mold in the molding process were studied.The main work as follows:At the temperature of 300°C⁴00°C,the corresponding flow stress curves were obtained under the conditions of 1×10^-4s^-11×10^-2s^-1.The constitutive equations of AZ80M forging magnesium alloys at high temperature were obtained by linear regression.The critical conditions of dynamic recrystallization were investigated using data obtained from thermal compression experiments.The dynamic recrystallization critical strain model and the dynamic recrystallization volume percentage model have been established.Through experiments,the dynamic recrystallization phenomenon of AZ80M magnesium alloy under forging and pressing was verified.The constitutive equation obtained from the experiment was imported into the DEFORM-3D simulation software.The optimum process parameter was obtained by changing parameters such as strain rate,strain temperature,and friction coefficient.It can be seen through simulation that the molding load is related to temperature and speed.The required forging pressure is relatively low when the rate is low and the temperature is high.According to the structural characteristics of the axle box body,forging piece and forming die are designed.Two sets of molds were designed.The second set of molds was analyzed for stress and service conditions.Through the simulation of the entire process,the dynamic parameters of the material are fed back to the mold.Through the analysis of the equivalent stress and strain of the mold,the most vulnerable position of the mold is obtained.Through the DEFORM-3D software platform,the dynamic recrystallization of the material in the hot compression process was simulated.It has been shown through studies that the non-uniformity of the deformation leads to non-uniform dynamic recrystallization percentages and non-uniform grain size.The dynamic recrystallization of the center is more complete and the grain size is smaller.