In order to solve the deformation defect, prior upsetting is split into upsetting of frustum anvil and sur-face flattening of flat anvil, and the forging process is modeled and simulated by DEFORM-3D finite element software.Based on the simulation result of stress and strain field in forging, it shows the detail about upsetting and surface flattening such as the parameters of frustum degree, reduction ratio, rotation mode of flat anvil and the down anvil shape.It obtains the rational forging parameters, provides the theoretical basis for the process de-sign of heavy disk forgings.

为了解决大型饼类锻件成形过程中因锻件变形不均匀引起的层状裂纹缺陷,通过DEFORM-3D有限元软件建立了排砧工艺的有限元模型,对传统下平台的排砧工艺进行了改进,提出了上下平砧的对称排砧工艺.模拟结果表明使用上下平砧且相邻道次错砧的对称排砧工艺方案能够较大提高锻件的应变均匀程度,减小裂纹倾向;在该工艺方案下采用15％压下率和400mm进砧量的工艺参数可在锻件心部获得稳定的压应力状态,同时具有较高的均匀变形率.通过产品试制和批量生产验证了该工艺方案的合理性.