中文摘要：

飞轮盘为大尺寸、变壁厚零件,采用先切割后焊接组装的加工方式,工序多,周期长,成本较高。采用冲锻成形新工艺成形该零件,并借助有限元模拟软件DEFORM-2D,对成形过程和模具关键尺寸进行了优化分析。为成形零件R5 mm内圆角,采用两步成形,即预成形时采用大半径圆角凸模拉深并利用镦粗凸模镦粗侧壁,终成形时将拉深凸模换为R5 mm圆角的凸模并将零件镦粗到要求尺寸。优化后的模拟结果显示成形良好,为实际生产提供了一定的参考依据。

英文摘要：

Flywheel panel is a part of large size and variable wall thickness. If the traditional process, such as cutting and weld-assembling is used, it demands more procedures, takes longer period and costs more. This research adopted a new stamping-forging process. The forming process and key mold dimensions were optimized utilizing DEFORM- 2D. In order to shape the inner fillet of R5 mm, a forming process with two-step was designed. A drawing-punch with bigger fillet drew the billet and an upsetting-punch compressed the wall first, and then the drawing-punch was replaced by another one which had a fillet of R5 mm and the wall was compressed until reaching the size requirements. The optimized simulated results were very well, which could provide a certain reference evidence to the practical industrial production.