第41卷第12期 Vol. 41No. 12
锻造
假压技术
FORGING & STAMPING TECHNOLOGY
2016年12月 Dec.2016
基于响应面法的汽车发电机磁极锻造成形工艺多目标优化
郝用兴，王超峰，张红艺，冯梅玲（华北水利水电大学机械学院，河南郑州450045）
摘要：针对汽车发电机磁极锻造成形过程中出现的填充不满、成形载荷过大、局部应力过大等缺陷，采用Deform软件对磁极锻造成形过程进行数值模拟分析。以降低未填充率、成形载荷和局部应力最大值为优化目标，以坏料直径、锻件温度、挤压速度和摩擦条件为优化变量，通过4因素5水平的中心复合试验，采用响应面法进行建模分析，最终得到3个优化目标的二阶响应面模型；对所建立的模型进行方差分析，通过模拟试验验证了该模型的准确性和可靠性。实际生产表明：采用优化工艺参数组合可以得到成形缺陷较小的磁极锻件，锻件成形精度可以达到±0.5mm；成形载荷和局部应力最大值得到降低；提高了模具寿命及生产效率。
关键词：发电机磁极；Defomm-3D；锻造成形；锻造缺陷；中心复合试验；多目标优化；响应面法 DOI: 10. 13330/j. issn. 1000-3940. 2016. 12. 001
中图分类号：TG316.3
文献标识码：A
文章编号：1000-3940（2016）12-0001-07
Multi-objective optimization onautomobilegeneratorpoleinforgingprocess
based onresponse surfacemethod
Hao Yongxing,Wang Chaofeng, Zhang Hongyi, Feng Meiling
( School of Mechanical Engineering, North China University of Water Resources and Electric Power, Zhengzhou 450045, China) Abstract : For the defects of under filling, heavy foming load and high peak value of local stress in the forging process of automobile gen-erator pole, the generator pole forging process was numerically simulated by the software of Deform. For the optimal objective to reduce umfilled rate, forming load and peak value of local stress, and the optimal variables with blank diameter, forging temperature, extruding speed and friction condition, the second order response surface model (RSM) of three optimal objectives was set up by central composite experiment design ( CCD) with four factors and five levels, and the analysis of variance ( ANOVA) of RSM was canried out. Furthermore, the variance analysis was performed on the established model, and its reliability and aceuracy were verified by simulated tests. The prac-tice production indicates that generator poles with less forming defects can be obtained by combining the optimized process parameters, and a high forging accuracy of 0. 5 mm can be achieved. Therefore, the peak values of forging load and local stress are deduced, the die life is prolonged and the production efficiency is improved.
asuodsa uorzugdo agaaqonu uaugadxa aisoduroa [ua :spaagap Sutroy Suaog (-tuoya( aod soauo spuom ay surfaoe method
随着汽车制造业的快速发展，对汽车零部件中形状复杂、成形精度要求高的零件的需求量日渐增大。对于机加工成本较高且难度大的锻件，对其锻造成形的精密度要求有所提高，以便降低零部件的生产成本和提高生产效率。磁极作为汽车发电机的
收稿日期：20160524；修订日期：20160816
基金项目：国家留学基金委地方合作项目（201308410091）；2015 年度河南省基础与前沿技术研究项目（152300410215）
作者筒介：帮用兴（1966-），男，博士，教授 E-mail: 392741383@ q- com
通讯作者：王超峰（1990-），男，额士万方甄据ail：wangchaodeng2006@163.com
关键零件，其锻造成形过程要求在保证成形质量的前提下，尽量提高成形精度、减少材料耗费和减少后续机加工量。磁极零件形状十分复杂，中间有1 个带孔的凸台，外围有6个均布的尖爪，中心孔与凸台上、下平面精度要求很高，必须通过机械加工实现；其它部位精度要求较低。达到精度要求的途径有两种：（1）锻造后机械加工：（2）提高锻造精度。传统的汽车发电机磁极铸造成形生产工艺，。
易
出现疏松、缩孔和偏析等缺陷，降低了磁极的力学性能。国内外近年来使用的磁极制造工艺有板料冲压成形工艺、热银冷精整成形工艺、分流式反挤压