微细制造新技术—半固态微成形研究进展
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摘要
介绍了半固态微成形的工艺适用性以及国内外研究进展,对半固态微成形目前研究的本构模型、尺度效应、摩擦机理、模具设计、工艺参数选择、微观组织等进行了总结论述,并对研究中存在的问题进行了简要分析。在此基础上着重论述了不同工艺条件下尺度效应的表现形式、不同本构模型的适用条件以及工艺参数的选择对材料流动和成形件质量的影响,指出了现有本构模型在描述半固态微成形过程中材料流动行为时的不足,提出了适用于半固态微成形本构模型理论研究的前景方向,另外介绍了在半固态微成形中存在明显的液相偏析,成形速度是影响液相偏析的主要原因。最后,对半固态微成形的研究进展进行了总结,并提出了目前该工艺存在的问题和未来应重点关注的方向。
The technological applicability of semi-solid microforming and the research progress at home and abroad were introduced.The constitutive model,scale effect,friction mechanism,die design,process parameter selection and micro-structure of semi-solid microforming were summarized and discussed,and the existing problems in the research were briefly analyzed.On this basis,the manifestation of scale effect under different process conditions,the applicable conditions of different constitutive models and the influence of process parameters selection on material flow and forming quality were emphatically discussed.The shortcomings of existing constitutive models in describing material flow behavior of semi-solid microforming process were pointed out,and the theoretical study of constitutive models suitable for semi-solid microforming was proposed.In addition,the obvious liquid segregation in semi-solid microforming was introduced,and the forming speed was the main factor affecting liquid segregation.Finally,the research progress of semi-solid microforming was summarized,and the existing problems and future directions of this process were put forward.
The technological applicability of semi-solid microforming and the research progress at home and abroad were introduced.The constitutive model,scale effect,friction mechanism,die design,process parameter selection and micro-structure of semi-solid microforming were summarized and discussed,and the existing problems in the research were briefly analyzed.On this basis,the manifestation of scale effect under different process conditions,the applicable conditions of different constitutive models and the influence of process parameters selection on material flow and forming quality were emphatically discussed.The shortcomings of existing constitutive models in describing material flow behavior of semi-solid microforming process were pointed out,and the theoretical study of constitutive models suitable for semi-solid microforming was proposed.In addition,the obvious liquid segregation in semi-solid microforming was introduced,and the forming speed was the main factor affecting liquid segregation.Finally,the research progress of semi-solid microforming was summarized,and the existing problems and future directions of this process were put forward.
引文
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[2]MENZ W,MOHR J,PAUL O.Microsystem technology[M].New Jersey:John Wiley&Sons,2008.
[3]ENGEL U,ECKSTEIN R.Microforming-from basic research to its realization[J].Journal of Materials Processing Technology,2002,125(2)35-44.
[4]穆阿姆梅尔·科驰,图格鲁勒·欧泽勒.微制造-微型产品的设计与制造[M].北京:国防工业出版社,2017.MUAMMER K,TUGRUL O.Micro-manufacturing:design and manufacturing of micro-products[M].Beijing:National Defense Industry Press,2017.
[5]郭斌,龚峰,单德彬.微成形摩擦研究进展[J].塑性工程学报,2009,16(4):146-151.GUO Bin,GONG Feng,SHAN Debin,et al.Research progress of tribology in microforming[J].Journal of Plastic Engineering,2009,16(4):146-151.
[6]ENGEL U.Tribology in microforming[J].Wear,2006,260(3):265-273.
[7]BAEK S W,OH S I,RHIM S H.Lubrication for micro forming of ultra thin metal foil[J].CIRP Annals-Manufacturing Technology,2006,55(1):295-298.
[8]STEINHOFF K,WEIDIG U,WEIKERT J.Micro semi-solid manufacturing-a new technological approach towards miniaturisation[J].Steel Research International,2004,75(8):611-619.
[9]FLEMINGS M C.Behavior of metal alloys in the semisolid state[J].Metallurgical Transactions B,1991,22(3):269-293.
[10]FAN Z.Semisolid metal processing[J].Metallurgical Reviews,2002,47(2):49-85.
[11]KIRKWOOD D H.Semisolid metal processing[J].Metallurgical Reviews,1994,39(5):173-189.
[12]李元东,刘兴海,张心龙,等.变形铝合金半固态近净成形研究进展[J].特种铸造及有色合金,2014,34(5):471-479.LI Yuandong,LIU Xinghai,ZHANG Xinlong,et al.Progress in semi-solid near-net forming of deformed aluminum alloys[J].Special Casting and Nonferrous Alloys,2014,34(5):471-479.
[13]KIM G Y,NI J,MAYOR R,et al.An experimental investigation on semisolid forming of micro/meso-scale features[J].Journal of Manufacturing Science&Engineering,2007,129(2):246-251.
[14]KIM G Y,KOC M,MAYOR R,et al.Modeling of the semi-solid material behavior and analysis of micro/meso-scale feature forming[J].Journal of Manufacturing Science&Engineering,2007,129(2):237-245.
[15]WU Y,KIM G Y,ANDERSON I E,et al.Experimental study on viscosity and phase segregation of Al-Si powders in microsemisolid powder forming[J].Journal of Manufacturing Science&Engineering,2010,132(1):11003-11007.
[16]WU Y.Development of novel semisolid powder processing for micromanufacturing[D].Ames:Iowa State University,2009.
[17]WU Y,KIM G Y,RUSSELL A M.Effects of mechanical alloying on an Al6061-CNT composite fabricated by semi-solid powder processing[J].Materials Science&Engineering A,2012,538(3):164-172.
[18]CHEN J J,YU H P,ZHAO Y Z.Experimental study on microscale filling capacity of semi-solid material[J].Die&Mould Technology,2010,(4):1-4.
[19]陈少东.ZL101半固态微成形本构模型与微齿轮挤压关键技术研究[D].上海:上海交通大学,2013.CHEN Shaodong.ZL101 semi-solid micro-shaping constitutive model and key technologies of micro-gear extrusion[D].Shanghai:Shanghai Jiao Tong University,2013.
[20]陈小庆.半固态ZL101材料微挤压成形尺寸精度的影响因素研究[D].上海:上海交通大学,2015.CHEN Xiaoqing.Influencing factors of dimensional accuracy in micro-extrusion forming of semisolid ZL101 materials[D].Shanghai:Shanghai Jiao Tong University,2015.
[21]LUO S,YU H,QIU H,et al.Microstructure evolution during remelting of high solid fraction ZL101 alloy[J].Journal of Shanghai Jiao Tong University,2017,22(6):712-718.
[22]任庆伟.超声振动辅助介观尺度半固态金属成形机理和实验研究[D].杭州:浙江大学,2016.REN Qingwei.Ultrasonic vibration-assisted meso-scale semi-solid metal forming mechanism and experimental study[D].Hangzhou:Zhejiang University,2016.
[23]唐培.A356合金微触变成形及其超声振动辅助机理研究[D].杭州:浙江大学,2012.TANG Pei.Micropatterning and auxiliary mechanism of ultrasonic vibration for A356 alloy[D].Hangzhou:Zhejiang University,2012.
[24]唐培,梅德庆,姚喆赫,等.半固态A356铝合金微凸台阵列触变成形充型过程数值模拟[J].中国有色金属学报,2012,22(12):3334-3341.TANG Pei,MEI Deqing,YAO Zhehe,et al.Numerical simulation of thixoforming filling process for semi-solid A356 aluminum alloy microprotrusion arrays[J].Chinese Journal of Nonferrous Metals,2012,22(12):3334-3341.
[25]MEI D Q,LI Y,YAO Z H,et al.Enhanced thermoelectric performance of n-type PbTe bulk materials fabricated by semisolid powder processing[J].Journal of Alloys&Compounds,2014,609(19):201-205.
[26]李洋.PbTe块体材料的半固态粉末成形制造及其热电性能研究[D].杭州:浙江大学,2015.LI Yang.Semi-solid powder manufacturing and thermoelectric properties of PbTe bulk materials[D].Hangzhou:Zhejiang University,2015.
[27]SHEN H,MEI D Q,YAO Z H,et al.Experimental study of the size effects in the upsetting of metallic materials[C]//The 7th International Conference on Micro Manufacturing.Illinois,2012.
[28]FU T,YUE X,WU H,et al.Enhanced thermoelectric performance of PbTe bulk meterials with figure of merit z T>2 by multifunctional alloying[J].Journal of Materiomics,2016,2(2):141-149.
[29]MEI D Q,WANG H,LI Y,et al.Microstructure and thermoelectric properties of porous Bi2Te2.85Se0.15 bulk materials fabricated by semisolid powder processing[J].Journal of Materials Research,2015,30(17):2585-2592.
[30]EGERER E,ENGEL U.Process characterization and material flow in microforming at elevated temperatures[J].Journal of Manufacturing Processes,2004,6(1):1-6.
[31]谢伟,于沪平.ZL101铝合金半固态微挤压流动性实验研究[J].锻压技术,2009,34(5):85-88.XIE Wei,YU Huping.ZL101 confinement semi-solid state microscopy,fluid dynamics experimental study[J].Forging&Stamping Technology,2009,34(5):85-88.
[32]雷晚勤.ZL101二次加热微正挤压试验研究[D].上海:上海交通大学,2008.LEI Wanqin.Experimental study on ZL101 secondary heating microextrusion[D].Shanghai:Shanghai Jiao Tong University,2008.
[33]陈金晶,于沪平,赵雅珠.微特征铝合金半固态流动性能试验研究[J].模具技术,2010,(4):1-4.CHEN Jinjing,YU Huping,ZHAO Yazhu.Experimental study on semi-solid flow properties of micro-featured aluminum alloy[J].Die and Mould Technology,2010,(4):1-4.
[34]王子叶,于沪平,赵军.ZL10合金微镦粗尺度效应研究[J].模具技术,2011,(3):1-5.WANG Ziye,YU Huping,ZHAO Jun.Research on coarse scale effect of ZL10 alloy micro-defect[J].Die and Mould Technology,2011,(3):1-5.
[35]TANG P,MEI D Q,YAO Z H,et al.Experimental study on size effects in microsemisolid forming of aluminum alloy[C]//The7th International Conference on Micro Manufacturing.Illinois,2012.
[36]TANG P,YAO Z H,ZHOU H H,et al.Experimental study on the reheating process for A356 alloy in thixoforming[J].Advanced Materials Research,2011,154-155:1324-1329.
[37]YAO Z H,MEI D Q,TANG P,et al.On the size effects in micro/meso semisolid extrusion-forging of A356 aluminum alloy[J].The International Journal of Advanced Manufacturing Technology,2014,73(9-12):1243-1252.
[38]NGUYEN T G,FAVIER D,SUERY M.Theoretical and experimental study of the isothermal mechanical behaviour of alloys in the semi-solid state[J].International Journal of Plasticity,1994,10(6):663-693.
[39]MADA M,AJERSCH F.Rheological model of semi-solid A356-SiC composite alloys.Part I:Dissociation of agglomerate structures during shear[J].Materials Science&Engineering A,1996,212(1):157-170.
[40]KIM G Y,NI J,KOC M.Modeling of the size effects on the behavior of metals in microscale deformation processes[J].Journal of Manufactoring Science and Engineering,2017,129(3):470-476.
[41]ARMSTRONG R W.On size effects in polycrystal plasticity[J].Journal of the Mechanics&Physics of Solids,1961,9(3):196-199.
[42]董湘怀,王倩,章海明,等.微成形中尺寸效应研究的进展[J].中国科学:技术科学,2013,43(2):115-130.DONG Xianghuai,WANG Qian,ZHANG Haiming,et al.Advances in research on size effect in microforming[J].Science in China:Technical Science,2013,43(2):115-130.
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