对大型全纤维曲轴TR镦锻装置中的模座进行了断裂失效分析，该装置在修改曲轴大法兰成形方式为全封闭成型后的第一次使用中，上、下模座均断裂。采用DEFORM3D软件对该全纤维钢曲轴镦锻成形进行数值模拟，计算获得锻件成形力和模具充填效果。采用IDears软件对曲轴TR镦锻装置进行结构强度计算，获得了镦锻装置的应力和变形状态，分析了模座发生断裂失效的原因。计算结果表明，模座实际的断裂部位和裂纹方向与强度分析结果吻合。

A failure investigation is conducted on the upsetbending equipment of a heavy crankshaft with continuous grain flow which is broken in the first use after the crankshaft flange is modified to deform in the die cavity. The forging process of the heavy crankshaft is simulated using the DEFORM3D software, through which the forming load and die filling are calculated. Using the IDears software, the structural strength calculation for the upsetbending equipment is performed. The stress field and displacement in the equipment are obtained. The failure analysis of the die base is accomplished. The analysis results show that the practical crack location and orientation in the die base are consistent with those in the structural strength calculation.

重庆市“十一五”科技攻关重大项目(CSTC,2005AA3012-4)；重庆市科委自然科学基金计划资助项目(CSTC,2007BB3135)；2006年度重庆大学自然科学青年基金资助项目