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曲軸熱鍛中表層局部微米級裂紋產(chǎn)生機理
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國家自然科學(xué)基金資助項目(10872221、10272120)


Mechanism of Micron Dimension Crack Appeared on Surface Layer of Crankshaft during Forging
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    摘要:

    基于實驗與數(shù)值模擬,從坯料體內(nèi)部自由缺陷在坯料變形過程中發(fā)生移動的角度來分析某曲軸連桿軸頸分模面內(nèi)側(cè)及過渡圓角處的微米級裂紋產(chǎn)生機理。提出將連續(xù)的坯料體分為表層優(yōu)質(zhì)層和中心次優(yōu)質(zhì)層的包覆結(jié)構(gòu)假設(shè),建立了相應(yīng)的數(shù)值模型,通過Deform 3D模擬出曲軸成形過程中這兩層金屬的流動與分布狀態(tài),獲得了內(nèi)部自由缺陷在鍛件中的堆積趨勢及原工藝下的成形速度場對優(yōu)質(zhì)層和次優(yōu)質(zhì)層流動的影響規(guī)律。結(jié)果表明:連桿軸頸分模面附近及過渡圓角處有中心次優(yōu)質(zhì)層金屬分布并裸露在鍛件表面,是自由缺陷富集的危險區(qū);終鍛成形過程中連桿軸頸橫截面上金屬的單方向流動加大了自由缺陷在危險區(qū)的聚集趨勢。實驗證明,出現(xiàn)的微米級裂紋是由從里層轉(zhuǎn)移到表層的、化合物成分為MnS和MoS的夾雜物在鍛件表層沿變形方向延伸而形成的一種發(fā)狀紋。

    Abstract:

    Based on the experimental and numerical simulation, the mechanism of micron dimension crack of crankshaft appeared in the area of inner parting plan of rod journal and transition fillet was analyzed in the view of the billet inner freedom defects’ transition during the forging. The billet was divided into two layers, named the outer higher quality layer and inner lower quality layer, and the corresponding finite element model of billet was built. The flow and distribution of two layers metals during forging were simulated by Deform 3D and the trend of accumulate of inner defects was achieved as well as the influence law of forging velocity on two layers’ flowing. The results showed that the inner low quality metal was distributed in the area of inner parting plan of rod journal and transition fillet and exposed on forging surface, which was the dangerous area. The metal on the cross section of rod journal flowing only at a direction intensified the trend of defect accumulating in the dangerous area. According to the experiment results, the micron dimension crack was a kind of hairline crack. The inclusion which contained MnS and MoS and transited into the surface of forging from inside of billet was extended along with the forming direction.

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周杰,張光華,權(quán)國政.曲軸熱鍛中表層局部微米級裂紋產(chǎn)生機理[J].農(nóng)業(yè)機械學(xué)報,2011,42(6):230-234. Zhou Jie, Zhang Guanghua, Quan Guozheng. Mechanism of Micron Dimension Crack Appeared on Surface Layer of Crankshaft during Forging[J]. Transactions of the Chinese Society for Agricultural Machinery,2011,42(6):230-234.

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