Research on the End Surface Dent of the Main Shaft Forging

Abstract

In the process of the stretching of the shaft forgings, if the process parameters are not properly selected, the end-face dent will take place. The end-face dent affects the performance of large forgings and leads to much material wasting. Finite element method was employed to perform numerical simulation of the stretching of a main shaft with an upper flat anvil and a lower V-shaped anvil. The orthogonal test table was designed by selecting the anvil width, the Reduction ratio and the feed as influencing factors. Accordingly, simulations were carried out to solve the end-face dent values under different parameter combinations. The analysis showed that the optimal parameter combination gave an anvil width ratio of 0.75, a Reduction ratio of 0.2, and an initial feed of 300 mm. Through extremum difference analysis, it was found that among the three factors are the feed, the reduction ratio, and the anvil width ratio in the decreasing order of the influence on the end- face dent. Comprehensive analysis showed that when the anvil is relatively narrow, increasing the relative feed can reduce the end-surface dent remarkably. It is advisable that during the stretching of shaft forgings with a flat upper anvil and a V-shaped lower anvil, the combination of the anvil width ratio of 0.75, the reduction ratio of 0.2, and increasing the feed can reduce the end-face dent, thereby reducing the end cutting and saving material costs.

Keywords

• dent
• finite element method
• heavy forgings
• stretching