为解决局部加载条件下铝合金大型锻件成形过程中微观组织不均匀与过渡区筋部充填不满的问题,借助于响应面法(RSM)与数值模拟相结合的策略对锻件局部加载成形工艺进行研究.以锻件微观组织均匀性和填充性作为质量评价目标,建立坯料温度、压力机速度、上模斜角角度、道次与质量指标之间的关系模型,并得到合理的工艺参数:坯料温度为440℃,压力机速度为10 mm/s,上模斜角角度为158°,3道次成形,各道次压下量分别为20,20和5 mm,将得到的工艺参数进行再模拟并应用于生产试制.对生产试制得到的锻件的典型截面进行组织观察.研究结果表明:模拟和实际生产的锻件微观组织均匀,分布规律一致,且锻件均充填完整,所提出的策略能有效对大型锻件局部加载成形宏、微观质量进行控制.%The strategy of combining response surface method with FEM was proposed to solve the problems under filling and micro-structural uniformity of 7050 aluminum alloy heavy forging, which was formed in the process of local loading. A response surface model was established, with the micro-structural uniformity and filling capacity as its evaluation objectives, and billet temperature, press velocity, angle of up die and parameter for passes were selected as the design variables of that model. Then the reasonable process parameters were obtained: billet temperature, press velocity and angle of up die are 440℃, 10 mm/s and 158°, respectively. The number of passes is three, the amount of each pass was 20, 20 and 5 mm. The parameters obtained above were applied in simulation and practical manufacture. The results show that not only the microstructure of forging obtained by simulation and manufacturer is uniform but also the distribution law of microstructure is consistent. The capacity of filling is good too. The quality of the microstructure and macrostructure of heavy forging can be effectively managed by the strategy proposed.
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