研究楔横轧成形的影响以及钛髋关节假体的锻造和模锻的形成

研究楔横轧成形的影响以及钛髋关节假体的锻造和模锻的形成(中文7000字,英文5500字)
为了降低锻造零件的生产成本，有可能采用不同的方法。尤其是像钛这样价格较高的材料，其材料成本占生产成本很大的一部分。因此，减少初始材料的用量可以显著降低总成本。为了改善这种状况，人们研究了现有的锻造工艺。对于钛型髋关节置换术，开发了一种锻造工艺。为了减少最初材料的需要，研究了楔横轧作为一种预成型的材料，并对其进行了模锻。不同的锻造阶段对最终结果的影响进行了详细分析和介绍。为了提高新开发的闪速锻造工艺的预测精度，减少模具设计的迭代循环，研究了锻造环境边界条件下的可行仿真参数，这是用有限元分析进行的，并且考虑到对形式填充、过程的稳定性、模具压力的影响。采用楔横轧、模锻和闪速制动以及新开发的锻造工艺可将闪速率从69%大幅降低到32%。
楔横轧、锻造、锻造序列发展、有限元模拟。
Investigating the effects of cross wedge rolling preforming operation and die forging with flash brakes on forging titanium hip implants
Bernd-Arno Behrens 1 & Malte Stonis2 & Thoms Blohm2 & Johannes Richter2

Received: 27 September 2016 / Accepted: 4 November 2016
# Springer-Verlag France 2016

Abstract To reduce production costs of forged parts, different approaches are possible. Especially for valu- able materials like titanium, material costs represent a large part of the production costs. Therefore, reducing the initial material can decrease the total costs signifi- cantly. In order to identify the potential for improve- ments, an existing forging sequence was in vestigated. For a titanium hip implant, a forging sequence was de- veloped. To reduce the initially needed material, cross wedge rolling as a preforming operation and die forging with flash brakes was investigated. The influence of the different stages on the final result was analysed and presented in detail. To  increase  the  prediction  accuracy of the newly developed flash-reduced forging  sequence and decrease iteration loops of die designs, feasible sim- ulation parameters considering the boundary  conditions of the forging environment were investigated. This is done using Finite Element Analysis (FEA), considering form filling, process stability, die stress and press forces. Using cross wedge rolling and die forging with flash brakes, the newly developed forging sequence re- duces the flash rate significantly from 69% to 32%.
Thoms Blohm blohm@iph-hannover.de