Defect Analysis and Optimization Improvements for Preforming Roll Forging A Crankshaft

After using performing roll forging,crankshaft forgings arise some defects of small ear.Analyzing the reasons,the main factors are the transition fillet and matching of roll forging passage.After the simulation and optimization improvements using DEFORM,it was found that the transition fillet 20 mm is optimum;when second roll forging,the most reasonable passage matching distance,namely,from the gripping end of the forgings to the roll forging die end is 45 mm.Through the test validation of production,improved process makes defect reach least.