外文翻譯--冷鍛技術(shù)的發(fā)展現(xiàn)狀與趨勢

1、<p><b>　　中文5100字</b></p><p><b>　　附錄1:翻譯（漢）</b></p><p>　　冷鍛技術(shù)的發(fā)展現(xiàn)狀與趨勢 </p><p>　　摘要： 冷鍛技術(shù)是一種精密塑性成形工藝，具有切削加工不可比擬的優(yōu)點(diǎn)，廣泛應(yīng)用于各種機(jī)械產(chǎn)品關(guān)鍵零部件的制造。本文從冷鍛零件的形狀、材料、工藝革新、

2、生產(chǎn)率、數(shù)值模擬技術(shù)和數(shù)字化/智能化設(shè)計(jì)技術(shù)應(yīng)用、以及優(yōu)化技術(shù)幾個(gè)方面綜合論述了冷鍛技術(shù)的發(fā)展現(xiàn)狀與趨勢。</p><p>　　關(guān)鍵詞： 冷鍛，工藝/模具設(shè)計(jì)，數(shù)值模擬，基于知識(shí)的工藝設(shè)計(jì)，設(shè)計(jì)優(yōu)化 。</p><p>　　冷鍛工藝是一種精密塑性成形技術(shù)，具有切削加工無可比擬的優(yōu)點(diǎn)，如制品的機(jī)械性能好，生產(chǎn)率高和材料利用率高，特別適合于大批量生產(chǎn)，而且可以作為最終產(chǎn)品的制造方法（net-s

3、hape forming），在交通運(yùn)輸工具、航空航天和機(jī)床工業(yè)等行業(yè)具有廣泛的應(yīng)用。當(dāng)前汽車工業(yè)、摩托車工業(yè)和機(jī)床工業(yè)的飛速發(fā)展，為冷鍛這一傳統(tǒng)的技術(shù)的發(fā)展提供了原動(dòng)力，例如，我國1999年摩托車的全國總產(chǎn)量就有1126萬多輛，而根據(jù)2000年的初步估計(jì)，我國汽車的總需求量到2005年將達(dá)到330萬輛，其中轎車130-140萬輛，僅汽車行業(yè)的鍛件需求在50-60萬噸以上。冷鍛技術(shù)在我國的起步雖然不算太晚，但發(fā)展速度與發(fā)達(dá)國家有很大的差距

4、。到目前為止，我國生產(chǎn)的轎車上的冷鍛件重量不足20Kg，相當(dāng)于發(fā)達(dá)國家的一半，開發(fā)潛力很大。加強(qiáng)冷鍛技術(shù)開發(fā)與推廣應(yīng)用是我國目前的一項(xiàng)緊迫任務(wù)。</p><p>　　1、冷鍛件的形狀越來越復(fù)雜 </p><p>　　冷鍛零件的形狀越來越趨于復(fù)雜，由最初的階梯軸、螺釘/螺母和導(dǎo)管等，發(fā)展到形狀復(fù)雜的零件，如圖1所示為不同尺寸的摩托車花鍵軸與花鍵套，花鍵軸的典型工藝為：正擠壓桿部-鐓粗中間頭部

5、分-擠壓花鍵；花鍵套的主要工藝為：反擠壓杯形件-沖底制成環(huán)型件-正擠壓軸套。如圖2所示為汽車輸出軸與輸入軸，以及其他冷鍛制品。如圖3所示為我國采用擺動(dòng)碾壓技術(shù)制成的各種汽車/摩托車用錐齒輪、螺旋錐齒輪和其他圓盤類零件，如圖4所示為日本某公司生產(chǎn)的冷鍛零件，圖4所示的渦旋增壓器，我國已經(jīng)列入國家“十五”攻關(guān)項(xiàng)目。目前圓柱齒輪的冷擠壓技術(shù)也成功用于生產(chǎn)。除黑色金屬外，目前銅合金、鎂合金和鋁合金材料的冷擠壓應(yīng)用也越來越廣泛。</p>

6、;<p>　　2、持續(xù)不斷的工藝革新 </p><p>　　冷精鍛是一種(近)凈形成形工藝。采用該方法成形的零件強(qiáng)度和精度高,表面質(zhì)量好。當(dāng)前國外一臺(tái)普通轎車采用的冷鍛件總量40～45Kg,其中齒形類零件總量達(dá)10Kg以上。冷鍛成形的齒輪單件重量可達(dá)1Kg以上、齒形精度可達(dá)7級(jí)。</p><p>　　持續(xù)不斷的工藝創(chuàng)新推動(dòng)了冷擠壓技術(shù)的發(fā)展，80年代以來，國內(nèi)外精密鍛造專家開

7、始將分流鍛造理論應(yīng)用于正齒輪和螺旋齒輪的冷鍛成形。分流鍛造的主要原理是在毛坯或模具的成形部分建立一個(gè)材料的分流腔或分流通道。鍛造過程中，材料在充滿型腔的同時(shí)，部分材料流向分流腔或分流通道。分流鍛造技術(shù)的應(yīng)用,使較高精度齒輪的少、無切削加工迅速達(dá)到了產(chǎn)業(yè)化規(guī)模。提出，對(duì)于長徑比為5的擠壓件，如活塞銷，采用軸向余料塊的方法通過軸向分流可以實(shí)現(xiàn)冷擠壓一次成形，而且凸模的穩(wěn)定性很好；對(duì)于扁平類的直齒輪成形，采用徑向余料塊也可以實(shí)現(xiàn)產(chǎn)品的冷擠壓成

8、形。</p><p>　　閉塞鍛造是在封閉凹模內(nèi)通過一個(gè)或兩個(gè)沖頭單向或?qū)ο驍D壓金屬一次成形,獲得無飛邊的近凈形精鍛件。一些轎車精密零件如行星和半軸齒輪、星形套、十字軸等如果采用切削加工方法,不僅材料利用率很低(平均不到40%),而且耗費(fèi)工時(shí)多,生產(chǎn)成本極高。國外采用閉塞鍛造技術(shù)生產(chǎn)這些凈形鍛件,省去絕大部分切削加工,成本大幅度降低。</p><p>　　冷鍛技術(shù)的發(fā)展主要是開發(fā)高附加值的

9、產(chǎn)品,降低生產(chǎn)成本,同時(shí), 它還在不斷地向切削、粉末冶金、鑄造、熱鍛、板料成形工藝等領(lǐng)域滲透或取而代之, 也可以和這些工藝相結(jié)合構(gòu)成復(fù)合工藝。提出的熱鍛-冷鍛復(fù)合塑性成形技術(shù)。熱鍛-冷鍛復(fù)合塑性成形技術(shù)是將熱鍛和冷鍛結(jié)合起來的一種新的精密金屬成形工藝，它充分利用了熱鍛和冷鍛各自的優(yōu)點(diǎn)：熱態(tài)下金屬塑性好，流動(dòng)應(yīng)力低，因此主要的變形過程用熱鍛來完成；冷鍛件的精度高，因此零件的重要尺寸用冷鍛工藝來最終成形零件。熱鍛-冷鍛復(fù)合塑性成形技術(shù)出現(xiàn)于

10、20世紀(jì)80年代，90年代以來取得了越來越廣泛的應(yīng)用，用該技術(shù)制造的零件，已取得了精度提高、成本降低的良好效果。</p><p>　　圖1 圖2</p><p>　　圖 3 圖 4</p><p>　　3、數(shù)值模擬技術(shù)用于檢驗(yàn)工

11、藝和模具設(shè)計(jì)的合理性</p><p>　　用冷鍛工藝成形零件時(shí)，由于金屬在冷態(tài)下發(fā)生塑性變形，其變形抗力很大，因此，零件的變形比較困難，變形過程中容易出現(xiàn)金屬充不滿、鍛件出現(xiàn)裂紋等缺陷。同時(shí)，過大的變形抗力會(huì)嚴(yán)重降低模具的使用壽命。長期以來,我國金屬塑性成形的工藝設(shè)計(jì)和模具設(shè)計(jì)一直采用傳統(tǒng)的憑經(jīng)驗(yàn)、實(shí)驗(yàn)方法。這種設(shè)計(jì)方法難以滿足凈形制造工藝的要求。</p><p>　　隨著計(jì)算機(jī)技術(shù)的飛速

12、發(fā)展和70年代塑性有限元理論的發(fā)展，許多塑性成形過程中很難求解的問題可以用有限元方法求解。在冷鍛成形工藝領(lǐng)域，通過建模和合適的邊界條件的確定, 有限元數(shù)值模擬技術(shù)可以很直觀地得到金屬流動(dòng)過程的應(yīng)力、應(yīng)變、模具受力、模具失效情況及鍛件可能出現(xiàn)的</p><p>　　缺陷情況。這些重要信息的獲得對(duì)合理的模具結(jié)構(gòu),模具的選材、熱處理及成形工藝方案的最終確定有著重要的指導(dǎo)意義。</p><p>　

13、　目前的有效的數(shù)值模擬軟件是以剛塑性有限元法為基礎(chǔ)建立起來的,這些軟件有:DEFORM,QFORM，F(xiàn)ORGE，MSC/SUPERFORM等。運(yùn)用有限元數(shù)值模擬技術(shù)可用于檢驗(yàn)工藝和模具設(shè)計(jì)的合理性。如提出了一種由空心坯成形直齒圓柱齒輪的新工藝: 預(yù)鍛分流區(qū)-分流終鍛, 用三維有限元數(shù)值模擬軟件DEFORM-3D 進(jìn)行了數(shù)值模擬研究, 得到了鍛造載荷-行程曲線以及整個(gè)成形過程的應(yīng)力、應(yīng)變、速度分布等, 并與傳統(tǒng)的閉式鐓擠工藝模擬的結(jié)果進(jìn)行

14、了比較。分析表明, 傳統(tǒng)的閉式鐓擠成形直齒圓柱齒輪, 成形載荷大, 不利于齒形的充填。采用預(yù)鍛分流區(qū)-分流終鍛新工藝, 可以大幅度降低成形載荷,并明顯改善材料的充填性, 可以獲得齒形角部飽滿的齒輪。 用三維大變形彈塑性有限元法對(duì)齒輪冷精鍛成形過程進(jìn)行了數(shù)值模擬,對(duì)以閉式模鍛為預(yù)鍛和以閉式模鍛、孔分流及約束分流為終鍛的兩步成形模式的變形流動(dòng)情況進(jìn)行了數(shù)值模擬分析。數(shù)值分析結(jié)果及工藝實(shí)驗(yàn)表明在終鍛中采取分流,尤其是約束孔分流措施對(duì)于降低工作

15、載荷和提高角隅充填能力等方面十分有效。</p><p>　　4、數(shù)字化智能設(shè)計(jì)系統(tǒng)的應(yīng)用</p><p>　　4.1 CAD/CAM技術(shù)在冷鍛成形工藝/模具設(shè)計(jì)中的應(yīng)用</p><p>　　為了適應(yīng)現(xiàn)代生產(chǎn)對(duì)鍛模開發(fā)的短周期、高質(zhì)量、低成本要求，將先進(jìn)的設(shè)計(jì)理論與方法以及計(jì)算機(jī)技術(shù)，尤其是CAD技術(shù)的引入傳統(tǒng)的鍛模設(shè)計(jì)過程是鍛模設(shè)計(jì)領(lǐng)域的必然趨勢。模具CAD技術(shù)以其

16、高自動(dòng)化、高精度和高效益等優(yōu)勢正持續(xù)推動(dòng)著傳統(tǒng)的模具設(shè)計(jì)與制造方法的變革。</p><p>　　自20世紀(jì)70年代以來，國外許多單位開始對(duì)鍛模CAD/CAM進(jìn)行了廣泛的研究，美國Ohio州的貝特爾—哥倫布實(shí)驗(yàn)室的T.Altan等人首先開發(fā)了軸對(duì)稱鍛模CAD系統(tǒng)。前蘇聯(lián)的捷捷林等專家系統(tǒng)研究了模鍛設(shè)計(jì)自動(dòng)化和最優(yōu)化原理，從方法學(xué)、算法模型等方面提出了全套的理論，并開發(fā)了回轉(zhuǎn)體類鍛件的自動(dòng)化設(shè)計(jì)系統(tǒng)。</p&g

17、t;<p>　　國內(nèi)在這方面的起步較晚，上海交通大學(xué)、清華大學(xué)、華中理工大學(xué)、哈爾濱工業(yè)大學(xué)和南昌大學(xué)等單位基于一定的平臺(tái)，開發(fā)了適用于不同種類鍛件的設(shè)計(jì)系統(tǒng)，但多數(shù)僅僅限于二維系統(tǒng)。到目前為止，雖然眾多的研究人員先后開發(fā)了適用于不同零件的鍛模設(shè)計(jì)系統(tǒng)，實(shí)現(xiàn)了工藝和模具設(shè)計(jì)若干環(huán)節(jié)的自動(dòng)化和智能化，但是尚未有成熟的鍛模CAD/CAM系統(tǒng)推向市場，許多工程設(shè)計(jì)人員只能采用通用的機(jī)械CAD/CAM軟件進(jìn)行結(jié)構(gòu)的詳細(xì)設(shè)計(jì)。<

18、;/p><p>　　4.2 基于知識(shí)的設(shè)計(jì)技術(shù)及其在冷鍛成形工藝/模具設(shè)計(jì)中的應(yīng)用</p><p>　　冷鍛成形工藝和模具設(shè)計(jì)是知識(shí)和經(jīng)驗(yàn)密集型的過程，模具設(shè)計(jì)人員在長期工作中積累的經(jīng)驗(yàn)與知識(shí)(Know-how)對(duì)模具設(shè)計(jì)有著十分重要的影響。傳統(tǒng)的CAD技術(shù)脫離了設(shè)計(jì)領(lǐng)域知識(shí),缺乏對(duì)設(shè)計(jì)過程知識(shí)的支持,難以勝任模具開發(fā)"高質(zhì)量、短周期、低成本"的要求。因此,需要將傳統(tǒng)的鍛模

19、CAD技術(shù)提升到基于知識(shí)的設(shè)計(jì)層次。而實(shí)現(xiàn)這一飛躍的途徑是將人工智能（Artificial Intelligence, AI）技術(shù)、基于知識(shí)的工程（Knowledge-based Engineering, KBE）技術(shù)引入冷鍛成形工藝/模具設(shè)計(jì)領(lǐng)域，與傳統(tǒng)的CAX技術(shù)相結(jié)合，開發(fā)基于知識(shí)的設(shè)計(jì)支持系統(tǒng)。</p><p>　　基于知識(shí)的工程（Knowledge Based Engineering, KBE）主要指應(yīng)

20、用知識(shí)來解決各種工程問題，是人工智能技術(shù)在工程中的應(yīng)用。由于冷鍛成形工藝/模具設(shè)計(jì)是一個(gè)包含了對(duì)知識(shí)的繼承、集成、創(chuàng)新和管理的復(fù)雜過程，引入基于知識(shí)的設(shè)計(jì)方法以后，跨領(lǐng)域?qū)＜业慕?jīng)驗(yàn)與知識(shí)共享能夠使得設(shè)計(jì)更加富有創(chuàng)造性和預(yù)見性，而且領(lǐng)域?qū)＜抑R(shí)在整個(gè)產(chǎn)品的設(shè)計(jì)生命周期內(nèi)的一致性保證了產(chǎn)品開發(fā)的成功率，大大節(jié)省了開發(fā)時(shí)間，提高了設(shè)計(jì)質(zhì)量。從而使整個(gè)設(shè)計(jì)模式從經(jīng)驗(yàn)設(shè)計(jì)向科學(xué)設(shè)計(jì)轉(zhuǎn)變。</p><p>　　美國哥倫布貝特

21、爾實(shí)驗(yàn)室開發(fā)出基于知識(shí)的預(yù)鍛幾何尺寸的設(shè)計(jì)系統(tǒng)，因設(shè)計(jì)預(yù)鍛件的形狀為空間幾何體，須對(duì)其幾何形狀進(jìn)行操作，故不能單純地用一般語言來描述推理過程。對(duì)于零件的幾何信息，采用框架方法表示，在框架中用不同的槽，定義出組成零件的基本成分和它們之間的拓?fù)潢P(guān)系。設(shè)計(jì)規(guī)則是用產(chǎn)生式規(guī)則表示，用OPS工具進(jìn)行推理。J. C. Choi和C. Kim開發(fā)了基于知識(shí)的冷鍛件和熱鍛件集成工序設(shè)計(jì)系統(tǒng)，并分別建立了冷、熱鍛件工藝設(shè)計(jì)規(guī)則。 </p>

22、<p>　　基于知識(shí)設(shè)計(jì)方法在冷鍛成形工藝及模具的設(shè)計(jì)中的應(yīng)用，將徹底改變塑性成形傳統(tǒng)的依靠設(shè)計(jì)人員個(gè)人經(jīng)驗(yàn)，設(shè)計(jì)過程中反復(fù)修改、設(shè)計(jì)效率不高的狀態(tài)。它使用人工智能、模式識(shí)別、機(jī)器學(xué)習(xí)等技術(shù)在設(shè)計(jì)過程中從系統(tǒng)知識(shí)庫中提取合適的知識(shí)指導(dǎo)冷鍛成形工藝及模具設(shè)計(jì)。目前，該項(xiàng)技術(shù)正在進(jìn)一步發(fā)展之中，近年來，基于知識(shí)設(shè)計(jì)方法已成為鍛造成形工藝/模具設(shè)計(jì)智能化技術(shù)研究的一個(gè)熱點(diǎn)課題。 </p><p><b&

23、gt;　　5、優(yōu)化技術(shù)的引入</b></p><p>　　隨著競爭的日益加劇，低成本、高質(zhì)量和高效率是制造業(yè)所追求的目標(biāo)。在鍛造行業(yè)，為提高設(shè)計(jì)效率、降低制造成本和提高產(chǎn)品質(zhì)量，必須對(duì)鍛造工藝過程中影響鍛件質(zhì)量的各項(xiàng)工藝參數(shù)進(jìn)行優(yōu)化。由于鍛造變形是一個(gè)十分復(fù)雜的問題，對(duì)于其工藝參數(shù)的優(yōu)化采用傳統(tǒng)的設(shè)計(jì)方法很難達(dá)到預(yù)期的效果，隨著計(jì)算機(jī)技術(shù)和塑性有限元理論和技術(shù)的不斷發(fā)展和日益完善，以有限元法為代表的數(shù)

24、值模擬方法已廣泛應(yīng)用于各種金屬成形問題的求解分析。因此，基于有限元分析的優(yōu)化設(shè)計(jì)方法在冷鍛成形工藝/模具設(shè)計(jì)中的應(yīng)用不僅是可能的，也是一種必然趨勢。</p><p>　　從實(shí)際應(yīng)用的角度來看，基于有限元分析的優(yōu)化方法中最具代表性的方法有基于靈敏度分析的優(yōu)化方法和基于目標(biāo)函數(shù)值的擬合優(yōu)化方法兩種。</p><p>　　基于靈敏度分析的優(yōu)化設(shè)計(jì)方法屬于梯度型優(yōu)化設(shè)計(jì)方法。該方法在具體實(shí)施時(shí)，首

25、先確定目標(biāo)函數(shù)和設(shè)計(jì)變量，然后找出它們之間的關(guān)系，推導(dǎo)目標(biāo)函數(shù)對(duì)設(shè)計(jì)變量的靈敏度—導(dǎo)數(shù)公式，根據(jù)設(shè)計(jì)變量的現(xiàn)有值求解出這些靈敏度信息，再利用優(yōu)化算法確定設(shè)計(jì)變量的最優(yōu)搜索方向，得到更優(yōu)的設(shè)計(jì)變量，再求解靈敏度信息，如此反復(fù)，直到優(yōu)化迭代收斂。</p><p>　　基于目標(biāo)函數(shù)值的擬合優(yōu)化方法來源于外推法。這種方法用簡單的插值函數(shù)來近似逼近目標(biāo)函數(shù)和設(shè)計(jì)變量之間的函數(shù)關(guān)系，通過求解這個(gè)近似函數(shù)的極值點(diǎn)來逼近真實(shí)函數(shù)

26、的極值點(diǎn)。該方法用在鍛造工藝參數(shù)優(yōu)化時(shí)，目標(biāo)函數(shù)值是通過有限元程序來實(shí)現(xiàn)的。目前，一些通用的有限元分析軟件如(DEFORM、Marc)已廣泛應(yīng)用于鍛造成形過程的數(shù)值模擬，可十分方便地計(jì)算出應(yīng)力、應(yīng)變等信息，因此，基于目標(biāo)函數(shù)值的擬合優(yōu)化方法可使有限元程序與優(yōu)化算法分離，適合不同的鍛造成形工藝，對(duì)于鍛造成形過程的參數(shù)優(yōu)化比較方便。</p><p>　　雖然基于有限元分析的鍛造工藝優(yōu)化技術(shù)的研究與應(yīng)用已取得了不少成果

27、，但目前仍處于起步階段。從目標(biāo)函數(shù)的構(gòu)建、優(yōu)化設(shè)計(jì)變量的選取到優(yōu)化方法的具體應(yīng)用可以看出,該領(lǐng)域的研究還存在一些問題。</p><p>　?。?）基于靈敏度分析的優(yōu)化方法的研究和應(yīng)用已取得了不少的成果，由于該方法屬于梯度型優(yōu)化方法，因此其收斂速度比較快。但它在實(shí)際的應(yīng)用中還存在一些缺點(diǎn)：在優(yōu)化設(shè)計(jì)過程中需要求解目標(biāo)函數(shù)相對(duì)于優(yōu)化設(shè)計(jì)變量的靈敏度信息(即導(dǎo)數(shù))，對(duì)于復(fù)雜的金屬塑性成形過程的靈敏度信息的推導(dǎo)困難。該方

28、法要求將求解靈敏度信息的程序代碼嵌入到數(shù)值分析程序代碼中，需要編寫有限元分析代碼和優(yōu)化算法代碼，編程工作量大。同時(shí)該方法優(yōu)化程序通用性差。</p><p>　?。?）基于目標(biāo)函數(shù)值的擬合優(yōu)化方法的優(yōu)點(diǎn)是優(yōu)化算法與有限元程序分離，可充分利用功能強(qiáng)大的商用有限元分析軟件的優(yōu)勢，該方法的通用性較強(qiáng)。它的主要缺點(diǎn)是收斂速度比較慢，同時(shí)由于在擬合問題中，但設(shè)計(jì)變量取得較多時(shí)，會(huì)出現(xiàn)許多復(fù)雜的問題如適定性問題，使得擬合過程失

29、敗。</p><p>　?。?）鍛造成形是一個(gè)復(fù)雜的過程，其理想鍛件不僅應(yīng)具有符合設(shè)計(jì)要求的精確外形，而且應(yīng)具有均勻的變形、合理分布的變形力和理想的質(zhì)量（無宏觀和微觀缺陷）等。上述各個(gè)方面，都是鍛造生產(chǎn)所追求的目標(biāo)，因此對(duì)鍛造過程優(yōu)化設(shè)計(jì)進(jìn)行多目標(biāo)優(yōu)化十分必要。目前這方面的研究比較少。</p><p><b>　　6、結(jié)論 </b></p><p&

30、gt;　　冷鍛技術(shù)成形精度比溫鍛和熱鍛都要高,在精密成形領(lǐng)域有著其獨(dú)特的優(yōu)勢。本文從冷鍛零件的形狀、材料、工藝革新、生產(chǎn)率、數(shù)值模擬技術(shù)和數(shù)字化/智能化設(shè)計(jì)技術(shù)應(yīng)用、以及優(yōu)化技術(shù)幾個(gè)方面綜合論述了冷鍛技術(shù)的發(fā)展現(xiàn)狀、分析了冷鍛技術(shù)目前存在的問題并指出了今后發(fā)展的方向。冷精鍛是一種(近)凈形成形工藝，有著十分廣闊的應(yīng)用前景。</p><p><b>　　附錄2：翻譯（英）</b></p&

31、gt;<p>　　State of The Art and Advance of Cold Forging Technology </p><p>　　Abstract: Cold forging is a kind of precise forming technology, and has the unique advantages compared to the traditional ma

32、chining technology. In this paper, the start of art and advance of the cold forging technology is systematically illustrated in the aspects of part shape, part material, process innovation, and production efficiency, app

33、lication of numerical simulation and knowledge-based design, and design optimization technology. </p><p>　　Keywords: cold forging, process/die design, numerical simulation, knowledge-based design, design opt

34、imization </p><p>　　The cold forging craft is one precise plastic forming technology, has the machining incomparable merit, like product machine capability good, the productivity high and the material use fa

35、ctor is high, suits specially in the mass production, moreover may take the final product the manufacture method (net-shape forming), in profession and so on transportation tool, aerospace and machine tool industry has t

36、he widespread application. The current automobile industry, the motorcycle industry and the m</p><p>　　Cold forging shape is more and more complex</p><p>　　The cold forging components shape more

37、 and more tends to complex, by initial steps and ladders axis, bolt/The nut and the drive pipe and so on, develop to the shape complex components, like chart 1 shows for the different size motorcycle spline shaft and the

38、 splined tube, the spline shaft typical craft is: Is pushing among the strut bracing department - upsetting the part - extrusion spline; The splined tube main craft is: The counter- extrusion cup shaped - flushes the bot

39、tom to make annular - </p><p>　　2 、Continues the unceasing craft innovation</p><p>　　The cold finish forge is one kind (is near) only forms the shape craft. A use this method forming the compone

40、nts intensity and the precision is high. The quality of surface is good. The current overseas ordinary passenger vehicle uses cold forging total quantity 40 ~ 45Kg.Tooth profile class components total quantity reaches ab

41、ove 10Kg. The cold forging forming gear single unit weight may reach above 1Kg; the tooth profile precision may reach 7 levels.</p><p>　　Continued the unceasing craft innovation to impel the cold extrusion t

42、echnology development, since 80's, Domestic and foreign precisely will forge the expert to start to diverge the forging theory to apply in the spur gear and the helical gear cold forging forming. The divergence forgi

43、ng main principle is partially establishes a material in the semi finished materials either the mold forming the divergence cavity or diverges the channel. In forging process, Material while filling cavity, the par</p

44、><p>　　Unenlightened forging is in seals up in the concave mold is unidirectional through either two drift or to approaches an extrusion metal forming, Obtains does not have the edge nearly only the shape fine

45、forging. Some passenger vehicle precise components like planets and rear axle shaft gear, star type wrap, cross axle and so on if uses the machining method, Not only the material use factor is very low (equally not to 40

46、%),Moreover consumes the man-hour, The production cost is extremely high. Ove</p><p>　　The cold forging technology development mainly is develops the high added value the product, Reduces the production cost

47、, At the same time, It also in unceasingly to the cutting, the powder metallurgy, the casting, the hot forging, domain seepage and so on sheet forming craft or displaces, Also may unify the constitution compound craft wi

48、th these crafts. Like the literature [4] proposed hot forging - cold forging compound plasticity forming technology. The hot forging - cold forging compound pla</p><p>　　Chart 1 Chart 2<

49、/p><p>　　Chart 3 Chart 4</p><p>　　3 、values simulations technology uses in the rationality which examines the craft and the mold designs.</p><p>　　When with cold forg

50、ing craft forming components, because the metal in cold condition under has the plastic deformation, its resistance to deformation very big, therefore, components distortion quite difficult, in the distortion process is

51、easy to appear the metal to be sufficient does not fill, the forging has flaw and so on crack. At the same time, the oversized resistance to deformation can seriously reduce the mold the service life. Since long ago, our

52、 country metal plasticity forming technol</p><p>　　Along with the computer technology rapid development and the 70's plastic finite element theory development, in many plasticity forming process is very

53、difficult the question which solves to be possible to use the finite element method to solve. In cold forging forming craft domain, through modeling and appropriate boundary condition determination, The finite element va

54、lue simulation technology may very direct-viewing obtain the flaw situation which the metal mobile process the stress, the strai</p><p>　　The present effective value simulation software was establishes take

55、just the plastic finite element method as the foundation. This software include: DEFORM, QFORM, FORGE, and MSC/SUPERFORM and so on. Use in the rationality utility the finite element value simulation technology which exam

56、ines the craft and the mold designs. Like the literature [ 5 ] proposed one kind forms the straight tooth cylindrical gears by the hollow billet the new craft: Hammers the divergence area - divergence end to ham</p>

57、;<p>　　4 、Digitized intelligences design system application</p><p>　　4.1 、CAD/CAM technology in cold forging forming craft/In mold design application</p><p>　　In order to adapt the modern

58、 production the short cycle which develops to the forging die, high grade, the low cost request, the advanced design theory and the method as well as computer technology, in particular the CAD technology introduction tra

59、dition forging die design process will be the forging die design domain inevitable trend. The mold CAD technology by its high superiority and so on automation, high accuracy and high benefit is continuing to impel the tr

60、aditional mold design and the ma</p><p>　　Since the 20th century 70's, the overseas many units have started to forging die CAD/CAM has conducted extensive research, American Ohio state Battle - Columbus

61、laboratory Thurman and so on Altan has first developed the axial symmetry forging die CAD system. Former Soviet Union's expert system and so on Czechoslovakia forest has studied the drop forging design automation and

62、 the optimized principle, from aspect and so on methodology, algorithm model proposed the complete set theory, and has deve</p><p>　　Domestic is late in this aspect start, Shanghai unit and so on Jiao tong U

63、niversity, Qinghai University, Huazhong University of Science and Technology, Harbin industrial university and Nanchang University based on the certain platform, developed has been suitable for the different type forging

64、 design system, but most was restricted in the two-dimensional system merely. So far, although the multitudinous researcher developed successively has been suitable for the different components forging die </p>&l

65、t;p>　　4.2 Based on knowledge design technology and its in cold forging forming craft/In mold design application。</p><p>　　The cold forging forming craft and the mold design are the knowledge and the exper

66、ience intensity process, the mold designs the personnel the experience and the knowledge which accumulates in the long lasting work (Know-how) has the extremely important influence to the mold design. The traditional CAD

67、 technology has been separated from the design domain knowledge. Lacks to designs of the process knowledge of the support. Is competent the mold to develop "high grade with difficulty, short cyclica</p><p

68、>　　Based on knowledge project (Knowledge Based Engineering, KBE) mainly refers to the application knowledge to solve each kind of project problem, is the artificial intelligence technology in the project application.

69、As a result of cold forging forming craft/The mold design was contains has inherited, integrated, the innovation and the management complex process to the knowledge, introduced based on after the knowledge design method,

70、 the cross domain expert's experience and knowledge sharing could </p><p>　　American Columbus the Battle laboratory develop hammers the geometry size in advance based on the knowledge the design system,

71、because designs the pre- forging the shape for the spatial geometry body, must carry on the operation to its geometry shape, therefore cannot purely describe the inference process with the general language. Regarding the

72、 components geometry information, uses the frame method to indicate that, in the frame with the different trough, defines the composition components the </p><p>　　Based on the knowledge design method in the

73、cold forging forming craft and in the mold design application, completely will change the plastic forming tradition the dependence to design the personnel individual experience, in the design process revises, the rated c

74、apacity not high condition repeatedly. It uses technology and so on artificial intelligence, pattern recognition, machine learning withdraws the appropriate knowledge instruction cold forging forming craft and the mold d

75、esign in the des</p><p>　　5 、Optimized technologies introduction</p><p>　　Intensifies day by day along with the competition, the low cost, high grade and the high efficiency is a goal which the

76、manufacturing industry pursues. In the forging profession, for the enhancement rated capacity, reduces the production cost and improves the product quality, must to forge in the technological process to affect the forgin

77、g quality each craft parameter to carry on the optimization. Because the forging distortion is an extremely complex question, uses traditional regarding its cra</p><p>　　Looked from the practical application

78、 angle that most has the representative based on in the finite element analysis optimized method to have based on the sector analysis optimized method and based on the goal function value fitting optimization method two

79、kinds.</p><p>　　Belongs to the gradient optimization design method based on the sector analysis optimized design method. This method when concrete implementation, first sets a target the function and the des

80、ign variable, then discovers between them the relations, the inferential reasoning objective function to designs the variable the sensitivity - derivative formula, according to designs the variable the existing value to

81、solve these sensitivity information, again uses the optimized algorithm determination des</p><p>　　Originates based on the goal function value fitting optimization method from the extrapolated method. This m

82、ethod is approximate with the simple interpolating function approaches between the objective function and the design variable functional relation, through solves this approximate function the extreme point to approach th

83、e real function the extreme point. This method uses when the forging craft parameter optimization, the goal function value is realizes through the finite element procedure.</p><p>　　Although has yielded many

84、 results based on the finite element analysis forging craft optimization technology research and the application, at present but still was at the start stage. Constructs, the optimized design variable selection from the

85、objective function may see to the optimized method concrete application, this domain research also has some problems.</p><p>　　(1) Has yielded many results based on the sector analysis optimized method resea

86、rch and the application, because this method belongs to the gradient optimization method, therefore it convergence rate quite is quick. But it also has some shortcomings in the actual application: Needs to solve the obje

87、ctive function in the optimized design process to be opposite in the optimized design variable sensitivity information (namely derivative), regarding complex metal plasticity forming process sensitivi</p><p>

88、;　　(2)Optimizes the algorithm and the finite element procedure based on the goal function value fitting optimization method merit separates, but fully uses the function formidable commercial finite element analysis softw

89、are the superiority, this method versatility is strong. Its main shortcoming is the convergence rate quite is slow, at the same time because in fitting question, when the design variable obtains much, can have many compl

90、ex questions suitable qualitative problems, causes the fitting </p><p>　　(3)Forges the forming is a complex process, its ideal forging not only should have conforms to the design request precise contour, mor

91、eover should have the even distortion, the reasonable distribution distortion strength and the ideal quality (does not have macroscopic and microscopic flaw) and so on. The above each aspect, all forges the goal which th

92、e production pursues, therefore to forges the process optimization design to carry on the multi-objectives to optimize extremely essential [10]. A</p><p>　　6、 Conclusions </p><p>　　The cold forg

93、ing technology forming precision warm hammers with the hot forging all must be higher than. Has its unique superiority in the precise formed domain. This article from the cold forging components shape, the material, the

94、craft innovates, the productivity, the value simulation technology and the digitization/The intellectualized design technology application, as well as the optimized technology several aspects syntheses will elaborate the