Optimization Design Of Flange Bolt Forging Process

Flange bolts are one of the fastener types.In the manufacturing process of flange bolts,flange bolts are generally produced by multi-step forging molding.There are many nonlinear problems in the forging process of flange bolts for example material nonlinearity,state nonlinear and geometrical nonlinearity.Various molding defects may occur during the forging process,such as folding defects,poor metal fluidity,fracture,lubrication failure etc.Therefore,the forging process is very important to the shaping quality of the flange bolt.In this paper,the forging process of flange bolts is studied.The forming process of flange bolts includes blanking,extrusion,head pre upsetting,head final forming,inverted hexagon,thread twisting and so on.In the forming process,extrusion,head pre upsetting,head final forming process has a great influence on the final quality of flange bolts,so we only consider the first three processes for the forging of flange bolts.In the past,the design and debugging of flange bolt forging process mainly depends on the experience of engineers and the " trial and error method",so that the debugging cycle is long,and the research and development cost is very high,and even lead to the failure of development,etc.With the continuous improvement of finite element simulation technology and the rapid development of computer technology and hardware,finite element simulation technology has brought an innovation to the field of engineering manufacturing.This paper is based on the theory of rigid plastic finite element method,the forging process of flange bolt is simulated by DEFORM software,and the feasibility of the forming process is evaluated.then DEFORM DOE module is used to optimize the forging process of flange bolts,and the design rule of the forging process of flange bolts is found,and the best process scheme that the minimum forming force meets the design requirements is obtained.Finally,Archard model is used to simulate and analyze the wear of the mold,and the wear depth of the mold is accurately predicted,which provides a reference value for mold structure design and material selection.