滑动摩擦接触对母线弯曲成形质量的影响
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摘要
目的研究滑动摩擦接触对1060纯铝母线弯曲成形质量的影响,得到表面质量更好的工件,降低废品率。方法采用自行设计的V形三点式自由弯曲成形的摩擦力测试装置,通过更换不同表面粗糙度的凹模圆角、不同润滑介质以改变接触状况,进行一系列摩擦试验。通过钨灯丝扫描显微镜获得板料弯曲件表面微观形貌图,通过MATLAB软件对所采集的数据进行曲线处理。结果得到不同粗糙度的凹模圆角以及不同润滑介质条件下的弯曲力-行程曲线。经测定,凹模圆角表面光滑时,无润滑状态下,最大摩擦力约为440 N;采用聚乙烯薄膜作为润滑介质,最大摩擦力约为100 N;采用聚四氟乙烯薄膜作为润滑介质时,最大摩擦力约为20 N。凹模圆角表面粗糙时,无润滑状态下,最大摩擦力约为235 N;采用聚四氟乙烯薄膜作为润滑介质时,最大摩擦力约为28 N。结论添加润滑介质可以有效降低板料与凹模圆角之间摩擦力大小,进而提高弯曲件表面成形质量。滑动摩擦条件下,无论光滑还是粗糙的凹模圆角,采取润滑措施均能有效提高弯曲成形工件的表面质量,且聚四氟乙烯薄膜作为润滑介质时,得到的板料表面质量最好。
The work aims to study the effect of sliding friction contact on the bending quality of 1060 pure aluminum busbar to get better surface quality and reduce reject rate. The self-designed friction force testing device for V-shaped three-point free bending forming was adopted to carry out a series of friction tests by changing the corner of the concave die with different surface roughness and different lubricating media to change the contact condition. The surface micro structure of sheet metal bending parts was obtained by tungsten filament scanning microscope. The collected data were fitted by MATLAB software. The curves of bending force and stroke under different roughness of concave die and different lubricating media were obtained. When die fillet surface was smooth and there was no lubrication state, the maximum friction size was about 440 N. When polyethylene film was used as lubricating medium, the maximum friction force size was about 100 N. When polytetrafluoroethylene film was used as lubricating medium, the maximum friction size was about 20 N. When the round angle surface of concave mould is rough, the maximum frictional force was about 235 N without lubrication. When polytetrafluoroethylene film was used as lubricating medium, the maximum frictional force was about 28 N. The addition of lubricating medium can reduce the friction between the plate and the concave die corner effectively, and then improve the forming quality of the surface of the bending parts. Under sliding friction conditions, the surface of bending parts can be effectively improved by the lubrication measures, whether concave die corner is smooth or rough, and the quality of the surface is the best when the PTEF film is used as the lubricating medium.
The work aims to study the effect of sliding friction contact on the bending quality of 1060 pure aluminum busbar to get better surface quality and reduce reject rate. The self-designed friction force testing device for V-shaped three-point free bending forming was adopted to carry out a series of friction tests by changing the corner of the concave die with different surface roughness and different lubricating media to change the contact condition. The surface micro structure of sheet metal bending parts was obtained by tungsten filament scanning microscope. The collected data were fitted by MATLAB software. The curves of bending force and stroke under different roughness of concave die and different lubricating media were obtained. When die fillet surface was smooth and there was no lubrication state, the maximum friction size was about 440 N. When polyethylene film was used as lubricating medium, the maximum friction force size was about 100 N. When polytetrafluoroethylene film was used as lubricating medium, the maximum friction size was about 20 N. When the round angle surface of concave mould is rough, the maximum frictional force was about 235 N without lubrication. When polytetrafluoroethylene film was used as lubricating medium, the maximum frictional force was about 28 N. The addition of lubricating medium can reduce the friction between the plate and the concave die corner effectively, and then improve the forming quality of the surface of the bending parts. Under sliding friction conditions, the surface of bending parts can be effectively improved by the lubrication measures, whether concave die corner is smooth or rough, and the quality of the surface is the best when the PTEF film is used as the lubricating medium.
引文
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[14]何霞,廖文玲,王国荣,等.润滑介质对摩擦性能影响差异分析[J].润滑与密封,2017,42(7):60-65.HE Xia,LIAO Wen-ling,WANG Guo-rong,et al.Analysis on influence difference of lubricating medium on tribological properties[J].Lubrication engineering,2017,42(7):60-65.
[15]赵振铎.金属塑性成形中的摩擦与润滑[M].北京:化学工业出版社,2004.ZHAO Zhen-duo.Friction and lubrication in metal plastic forming[M].Beijing:Chemical Industry Press,2004.
[16]BECH J,BAY N,ERIKSEN M.A study of mechanisms of liquid lubrication in metal forming[J].CIRP annals-manufacturing technology,1998,47(1):221-226.
[17]WOJTOWICZ W J.Sliding friction test for metalworking lubricants[J].Lubrication engineering,1955,11:174-177.
[2]HILL R.The mathematical theory of plasticity[M].Oxford:Clarendon Press,1950.
[3]摩尔.摩擦学原理和应用[M].北京:机械工业出版社,1982.MOLE.Principles and applications of tribology[M].Beijing:China Machine Press,1982.
[4]瓦伦丁L波波夫.接触力学与摩擦学的原理及其应用[M].北京:清华大学出版社,2011.VALENTIN L P.Contact mechanics and friction physical principles and applications[M].Beijing:Tsinghua University Press,2011.
[5]SCHEY J A.Tribology in metalworking[M].Ohio:American Society for Metals,1983.
[6]杨本杰,刘小君,董磊,等.表面形貌对滑动接触界面摩擦行为的影响[J].摩擦学学报,2014,34(5):553-560.YANG Ben-jie,LIU Xiao-jun,DONG Lei,et al.Effect of surface topography on the interface tribological behavior of sliding contact[J].Tribology,2014,34(5):553-560.
[7]原大宁,刘丽兰,刘宏昭,等.滑动摩擦模型研究现状[J].系统仿真学报,2009,21(4):1142-1147.YUAN Da-ning,LIU Li-lan,LIU Hong-zhao,et al.Progress of pre-sliding friction model[J].Journal of system simulation,2009,21(4):1142-1147.
[8]赖联锋,高诚辉,黄健萌.粗糙表面滑动摩擦接触模型研究的进展[J].中国工程机械学报,2011,9(2):134-138.LAI Lian-feng,GAO Cheng-hui,HUANG Jian-meng.Advances on sliding frictional contact models of rough surfaces[J].Chinese journal of construction machinery,2011,9(2):134-138.
[9]MFANAfiKILE D M.Sensitivity analysis of stamping processes using various friction models appropriate for non-stationary contact problems[J].Journal of the franklin institute,2009,346(8):830-839.
[10]LEE B H,KEUM Y T,WAGONER R H.Modeling of the friction caused by lubrication and surface roughness in sheet metal forming[J].Journal of materials processing technology,2002,130-131(1):60-63.
[11]赵振铎,王家安,王丽君.金属塑性成形平均摩擦系数与接触压力的关系研究[J].锻压装备与制造技术,2006,41(1):40-43.ZHAO Zhen-duo,WANG Jia-an,WANG Li-jun.Research on the relationship between average friction coefficient and contact press in metal plastic forming[J].China metalforming equipment&manufacturing thchnology,2006,41(1):40-43.
[12]AZUSHIM A A,UDA M,KUDO H.An interpretation of the speed dependence of the coeffcient of friction under the micro PHL condition in sheet drawing[J].Annals of the CIRP,1991,40(1):227-230.
[13]邹琼琼,黄继龙,龚红英,等.塑性成形中的摩擦与润滑问题[J].热加工工艺,2016(23):18-20.ZOU Qiong-qiong,HUANG Ji-long,GONG Hong-ying,et al.Problems of friction and lubrication in plastic forming[J].Hot working technology,2016(23):18-20.
[14]何霞,廖文玲,王国荣,等.润滑介质对摩擦性能影响差异分析[J].润滑与密封,2017,42(7):60-65.HE Xia,LIAO Wen-ling,WANG Guo-rong,et al.Analysis on influence difference of lubricating medium on tribological properties[J].Lubrication engineering,2017,42(7):60-65.
[15]赵振铎.金属塑性成形中的摩擦与润滑[M].北京:化学工业出版社,2004.ZHAO Zhen-duo.Friction and lubrication in metal plastic forming[M].Beijing:Chemical Industry Press,2004.
[16]BECH J,BAY N,ERIKSEN M.A study of mechanisms of liquid lubrication in metal forming[J].CIRP annals-manufacturing technology,1998,47(1):221-226.
[17]WOJTOWICZ W J.Sliding friction test for metalworking lubricants[J].Lubrication engineering,1955,11:174-177.