金属环件轧制过程的动力显式算法有限元模拟
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摘要
环件轧制是一种生产无缝环件的特种加工工艺，它是通过局部连续轧制方法，将小直径厚截面的环形毛坯逐渐辗扩成大直径薄截面的环件，它具有省力，节能、节材、生产率高、生产成本低、产品范围广等显著特点，在工业领域有着广泛的应用。
本文基于环件轧制理论和有限元理论，建立了环件轧制过程有限元分析计算模型，并使用动力显式算法进行了计算。通过模拟分析比较，揭示出了环件轧制过程中的金属流动规律：轧制时，环件外侧的变形最大，厚向中心部位变形最小，内侧的变形程度介于中间；环件内外环面的压应力分布和变化规律：在垂直于环件轴线的对称面上，压应力分布近似对称状态，而且在对称面上的应力最大，往端面方向开始减小；指出了环件轧制中轧辊与环件摩擦对环件成形的影响：对于环件的宽展变形，摩擦的影响很小，可以忽略；分析了环件进给速度对环件成形的影响并阐述了环件厚向中心部位凹陷产生的原因，提出防止凹陷的措施：在轧制时，尽量使用快的进给速度有利于防止端面凹陷的产生；研究了导向辊位置对环件成形以及轧辊受力的影响：导向辊的位置对环件的宽展变形影响很小，但对轧辊的受力影响较大，当导向辊的中心位置位于毛坯初始中心位置之上时，驱动辊和芯辊的受力相对较小，这是导向辊导向时优先考虑的位置。
本文使用有限元分析方法，对异形截面环件过程工艺参数进行了设计和规划，模拟出了环件轧制过程中出现的缺陷，阐明了缺陷产生的原因及改进方法；利用设计好的工艺参数进行分析的结果和试验结果进行了比较，两者达到了较好的吻合。
Ring rolling is a specialized rolling process for manufacturing seamless rings, in which the diameter of the ring increases as the ring cross-section decreases by rolling. It has many characteristics such as saving forming force and production cost, increasing utilization ratio of energy and material, improving productivity and widening processing range of ring products etc. It is widely employed in many industrial domains.
In this paper, based on the theories of finite element method and the theories of ring rolling, the calculation model of ring rolling processes has been established and calculated by dynamic algorithm finite element program. Detailed numerical results are obtained: the deformation of the ring-driven roll interface is larger than that of the ring-idle roll interface. In the center domain, the deformation of the ring is smallest. The distribution of normal pressure stress along the ring-roll interface is radial symmetry and the pressure stress is largest in the symmetry plane. The effect of the friction between rolls and ring can be ignored and the effect of the spread velocity of rolling on the deforrration of ring is illustrated. Then the cause and elimination of fishtail defect are investigated: a relative faster spread velocity is helpful 10 eliminating the defect. The position of the guide roll almost has no effect on the deformation of the ring, but has the important effect on the force appeared in the roll. Then the optimal position has been suggested the center position of the guide roll should be over the center of the green blank of ring.
The simulation of profile ring rolling has been performed to get the process parameters. As a result, the rolling defect has appeared and the cause has been illustrated. The result has a good agreement with the experimental data.
本文基于环件轧制理论和有限元理论，建立了环件轧制过程有限元分析计算模型，并使用动力显式算法进行了计算。通过模拟分析比较，揭示出了环件轧制过程中的金属流动规律：轧制时，环件外侧的变形最大，厚向中心部位变形最小，内侧的变形程度介于中间；环件内外环面的压应力分布和变化规律：在垂直于环件轴线的对称面上，压应力分布近似对称状态，而且在对称面上的应力最大，往端面方向开始减小；指出了环件轧制中轧辊与环件摩擦对环件成形的影响：对于环件的宽展变形，摩擦的影响很小，可以忽略；分析了环件进给速度对环件成形的影响并阐述了环件厚向中心部位凹陷产生的原因，提出防止凹陷的措施：在轧制时，尽量使用快的进给速度有利于防止端面凹陷的产生；研究了导向辊位置对环件成形以及轧辊受力的影响：导向辊的位置对环件的宽展变形影响很小，但对轧辊的受力影响较大，当导向辊的中心位置位于毛坯初始中心位置之上时，驱动辊和芯辊的受力相对较小，这是导向辊导向时优先考虑的位置。
本文使用有限元分析方法，对异形截面环件过程工艺参数进行了设计和规划，模拟出了环件轧制过程中出现的缺陷，阐明了缺陷产生的原因及改进方法；利用设计好的工艺参数进行分析的结果和试验结果进行了比较，两者达到了较好的吻合。
Ring rolling is a specialized rolling process for manufacturing seamless rings, in which the diameter of the ring increases as the ring cross-section decreases by rolling. It has many characteristics such as saving forming force and production cost, increasing utilization ratio of energy and material, improving productivity and widening processing range of ring products etc. It is widely employed in many industrial domains.
In this paper, based on the theories of finite element method and the theories of ring rolling, the calculation model of ring rolling processes has been established and calculated by dynamic algorithm finite element program. Detailed numerical results are obtained: the deformation of the ring-driven roll interface is larger than that of the ring-idle roll interface. In the center domain, the deformation of the ring is smallest. The distribution of normal pressure stress along the ring-roll interface is radial symmetry and the pressure stress is largest in the symmetry plane. The effect of the friction between rolls and ring can be ignored and the effect of the spread velocity of rolling on the deforrration of ring is illustrated. Then the cause and elimination of fishtail defect are investigated: a relative faster spread velocity is helpful 10 eliminating the defect. The position of the guide roll almost has no effect on the deformation of the ring, but has the important effect on the force appeared in the roll. Then the optimal position has been suggested the center position of the guide roll should be over the center of the green blank of ring.
The simulation of profile ring rolling has been performed to get the process parameters. As a result, the rolling defect has appeared and the cause has been illustrated. The result has a good agreement with the experimental data.
引文
[1] Mamalis A G, Johnson W, Hawkyard J B. Ring Rolling: Literature Review and Some Recent Experiment Result. Metallurga and Metal Forming.1976:132-40
[2] Johnson W, Mamalis A G. Rolling of Rings. International Metals Reviews,1979(4): 137-148
[3] 华林，黄兴高，朱春东．环件轧制理论和技术．北京：机械工业出版社，2001年
[4] 华林，赵仲治．环件辗扩成形及其在汽车工业中应用．汽车工程，1993，15(4)：250-256
[5] 华林，赵仲治，张猛．后桥从动伞齿轮锻件辗扩毛坯设计．汽车工艺．1991．(1)：11—13
[6] Eruo E. Shivpuri R. A Summary of Ring Rolling Technology-Ⅱ, Recent Trends in Machines, Process and Production Lines. Int.J.Mach.Tools Manfufact, 1992,32(3):399-413
[7] 华林．环件轧制成形原理和技术设计方法：[博士学位论文]．西安：西安交通大学，2000
[8] Bouncly P, Oudin J, Ravalard Y. New Approach for Predicting Ring Rolling with New Wax-Based Model Material on A Flexible Experimental Machine.J. Mech. Working Tech..1988,16:119-143
[9] Johnson W, Needham G. Experiments on Ring Rolling. Int.J.Mech..Sci.,1968,(10):95-113
[10] Johnson W, Needham G. Plastic Hinges in Ring Indentation in Relation to Ring Rolling. Int.J.Mech.Sci., 1968,(10):487-490
[11] Johnson W, Needham G. An Experimental Investigation into the Process of Ring or Metal tyre Rolling. Int.J.Meeh.Sci.,1968,(10),455-466
[12] Hawkyard J B, Johnson W, Kirhland J, Appleton E. Analyses for Roll Force and Torque in Ring Rolling, with Some Supporting Experiments.Int.J.Mech.Sci., 1973,(15):873-893
[13] Mamalis A G, Hawkyard J B, Johnson W. Spread and Flow Patterns in Ring Rolling. Int.J.Mech.Sci., 1976,(18): 11-16
[14]Mamalis A G, Hakyard J B, Johnson W. On the Pressure Distribution between Stock and Rolls in Ring Rolling. Int. J.Mech.Sci, 1976,4(18):184-195
[15]Mamalis A G, Johnson W, Hawkyard J B. Pressure Distribution, Roll Force and Torque in Cold Ring Rolling.J.Mech.Eng.Sci.,1976,4(18):196-209
[16]Mousssa G, Hawkyard J B. Investigation into the Multi-Stage Ring Rolling of Aluminum Bicycle Wheel Rims. Int.J.Mech.Sci.,1986,12(28):841-852
[17]许思广，连家创．环件轧制中宽展变形的实验研究．东北重型机械学院学报，1991，(2)：107-113
[18]许思广，连家创．环件轧制应变分布的试验研究．锻压技术，1991，(1)：35-39
[19]陈学胜，赵仲治．用上限法分析伞齿轮坯闭式环轧时的力能参数．农业机械学报，1994，(2)：101-106
[20]周存龙，姚开云，孙斌煜，李国桢．用上限元法计算L型截面环件在轧制过程中的轧制力．太原重型机械学院学报，1999，(3)：272-277
[21]Yang D Y, Kim K H. Rigid-Plastic Finite Element Analysis of Plane Strain Ring Rolling. International Journal of Mechanical Science,1988,30(8):571-580.
[22]Naksoo Kim, Susumu Machida, Shiro Kobayshi. Ring Rolling Process Simulation by the Three Demension Finite Element Method.Int.J.Mach.Tools. 1990.30(4):569-577.
[23]Yang D Y, Kim.K.H. Hawkyard J B. Simulation of T-Section Profile Ring Rolling by the 3-D Rigid-Plastic Finite Element Method. Int J.Mech,Sci, 1991,33(7):541-550.
[24]Hu Z M, Pillinger I, Hartley P, MeKenzie S, Spence P J. Three-Dimension finite Modeling of Ring Rolling. Journal of Materials Processing Technology, 1994,(45):143-148.
[25]Lim T, Pillinger I, Hartley P. A Finite-element Simulation of Profile Ring Rolling Using A Hybrid Mesh Model. Journal of Matemils Processing Technology, 1998,80-81:199-205
[26]Sawamiphakdi K, Pauskar P M, Jin D Q, Lahoti GD. Ring Rolling Process Modeling Using Explicit Finite Element Analysis. Advanced Technology of Plasitcity,2002,(1).
[27]Davey K, Ward M J. A Practical Method For Finite Element Ring Rolling Simulation Using The ALE Flow Formulation. Int.J.Mech.Sci.,2002,(44): 165-190.
[28]Xu S G, Lian J C, Hawkyard J B. Simulation of Ring Rolling Using A Rigid- Plastic Finite Element Model. Int. J.Mech.Sci,1991,33(5):393-401.
[29]许思广，姚开云．环件轧制过程计算机模拟．重型机械，1994，(1)
[30]许思广，连家创，环件轧制的热刚塑性耦合有限元分析．机械工程学报，1994，30(2)：87—92
[31]解春雷．环件轧制过程刚粘塑性动力显示算法有限元模拟：[博士学位论文]．武汉：华中理工大学，1997
[32]解春雷，李尚健，黄树槐．金属刚粘塑性变形的能量泛函与动力显式算法有限元分析，固体力学学报1998，19(2)
[33]郭正华，解春雷，李尚健，黄树槐．动态有限元模拟与环轧控制策略，锻压机械，1999，(6)
[34]解春雷，李尚健，黄树槐．辗环过程动力有限元分析中的抱辊约束，锻压机械，1997，(3)
[35]郭正华，解春雷；李尚健．环件热轧动态过程有限元模拟．塑性工程学报，1999，(6)
[36]郭正华，解春雷，李尚健．环件轧制动态过程刚黏塑陛有限元反向模拟．全国锻压学术年会论文，1999
[37]李尚健．金属塑性成形过程模拟．北京：机械工业出版社，1999
[38]蒋友谅．非线性有限元法．北京：北京工业大学出版社，1988
[39]谢水生．王祖唐．金属塑性成形工步的有限元数值模拟．北京：冶金工业出版社，1997
[40]刘相华．刚塑性有限元法及其在轧制中的应用．北京：冶金工业出版社，1994
[41]谢贻权，何福保．弹性和塑性力学中的有限单元法．北京：机械工业出版社，1981
[42]徐次达，华伯浩．固体力学有限元理论、方法及程序．北京：水利电力出版社，1983
[43]庄茁译．连续体和结构体的非线性有限元．北京：清华大学出版社。2002
[44]Ted Belytschko, Wing Kam Liu, Brian Moran. Nonlinear Finite Element
for Continua and Structures.Northwestern University, 1998
[45]Owen D R J, Hinton E. Finite Elements In Plasticity. Pineridge Press Limited Swansea, U.K. 1980
[46]庄茁等译．ABAQUS／Standard有限元软件入门指南．北京：清华大学出版社，1998
[47]庄茁等译．ABAQUS／Explicit有限元软件入门指南．北京：清华大学出版社，1998
[48]Abaqus Analysis User's Manual. ABQUS Corp.,2003
[49]Abaqus/CAE User's Manual. ABQUS Corp.,2003
[50]华林，赵仲治．轧辊变形对环件精度的影响及其补偿．锻压技术，1999，(2)：39—41
[2] Johnson W, Mamalis A G. Rolling of Rings. International Metals Reviews,1979(4): 137-148
[3] 华林，黄兴高，朱春东．环件轧制理论和技术．北京：机械工业出版社，2001年
[4] 华林，赵仲治．环件辗扩成形及其在汽车工业中应用．汽车工程，1993，15(4)：250-256
[5] 华林，赵仲治，张猛．后桥从动伞齿轮锻件辗扩毛坯设计．汽车工艺．1991．(1)：11—13
[6] Eruo E. Shivpuri R. A Summary of Ring Rolling Technology-Ⅱ, Recent Trends in Machines, Process and Production Lines. Int.J.Mach.Tools Manfufact, 1992,32(3):399-413
[7] 华林．环件轧制成形原理和技术设计方法：[博士学位论文]．西安：西安交通大学，2000
[8] Bouncly P, Oudin J, Ravalard Y. New Approach for Predicting Ring Rolling with New Wax-Based Model Material on A Flexible Experimental Machine.J. Mech. Working Tech..1988,16:119-143
[9] Johnson W, Needham G. Experiments on Ring Rolling. Int.J.Mech..Sci.,1968,(10):95-113
[10] Johnson W, Needham G. Plastic Hinges in Ring Indentation in Relation to Ring Rolling. Int.J.Mech.Sci., 1968,(10):487-490
[11] Johnson W, Needham G. An Experimental Investigation into the Process of Ring or Metal tyre Rolling. Int.J.Meeh.Sci.,1968,(10),455-466
[12] Hawkyard J B, Johnson W, Kirhland J, Appleton E. Analyses for Roll Force and Torque in Ring Rolling, with Some Supporting Experiments.Int.J.Mech.Sci., 1973,(15):873-893
[13] Mamalis A G, Hawkyard J B, Johnson W. Spread and Flow Patterns in Ring Rolling. Int.J.Mech.Sci., 1976,(18): 11-16
[14]Mamalis A G, Hakyard J B, Johnson W. On the Pressure Distribution between Stock and Rolls in Ring Rolling. Int. J.Mech.Sci, 1976,4(18):184-195
[15]Mamalis A G, Johnson W, Hawkyard J B. Pressure Distribution, Roll Force and Torque in Cold Ring Rolling.J.Mech.Eng.Sci.,1976,4(18):196-209
[16]Mousssa G, Hawkyard J B. Investigation into the Multi-Stage Ring Rolling of Aluminum Bicycle Wheel Rims. Int.J.Mech.Sci.,1986,12(28):841-852
[17]许思广，连家创．环件轧制中宽展变形的实验研究．东北重型机械学院学报，1991，(2)：107-113
[18]许思广，连家创．环件轧制应变分布的试验研究．锻压技术，1991，(1)：35-39
[19]陈学胜，赵仲治．用上限法分析伞齿轮坯闭式环轧时的力能参数．农业机械学报，1994，(2)：101-106
[20]周存龙，姚开云，孙斌煜，李国桢．用上限元法计算L型截面环件在轧制过程中的轧制力．太原重型机械学院学报，1999，(3)：272-277
[21]Yang D Y, Kim K H. Rigid-Plastic Finite Element Analysis of Plane Strain Ring Rolling. International Journal of Mechanical Science,1988,30(8):571-580.
[22]Naksoo Kim, Susumu Machida, Shiro Kobayshi. Ring Rolling Process Simulation by the Three Demension Finite Element Method.Int.J.Mach.Tools. 1990.30(4):569-577.
[23]Yang D Y, Kim.K.H. Hawkyard J B. Simulation of T-Section Profile Ring Rolling by the 3-D Rigid-Plastic Finite Element Method. Int J.Mech,Sci, 1991,33(7):541-550.
[24]Hu Z M, Pillinger I, Hartley P, MeKenzie S, Spence P J. Three-Dimension finite Modeling of Ring Rolling. Journal of Materials Processing Technology, 1994,(45):143-148.
[25]Lim T, Pillinger I, Hartley P. A Finite-element Simulation of Profile Ring Rolling Using A Hybrid Mesh Model. Journal of Matemils Processing Technology, 1998,80-81:199-205
[26]Sawamiphakdi K, Pauskar P M, Jin D Q, Lahoti GD. Ring Rolling Process Modeling Using Explicit Finite Element Analysis. Advanced Technology of Plasitcity,2002,(1).
[27]Davey K, Ward M J. A Practical Method For Finite Element Ring Rolling Simulation Using The ALE Flow Formulation. Int.J.Mech.Sci.,2002,(44): 165-190.
[28]Xu S G, Lian J C, Hawkyard J B. Simulation of Ring Rolling Using A Rigid- Plastic Finite Element Model. Int. J.Mech.Sci,1991,33(5):393-401.
[29]许思广，姚开云．环件轧制过程计算机模拟．重型机械，1994，(1)
[30]许思广，连家创，环件轧制的热刚塑性耦合有限元分析．机械工程学报，1994，30(2)：87—92
[31]解春雷．环件轧制过程刚粘塑性动力显示算法有限元模拟：[博士学位论文]．武汉：华中理工大学，1997
[32]解春雷，李尚健，黄树槐．金属刚粘塑性变形的能量泛函与动力显式算法有限元分析，固体力学学报1998，19(2)
[33]郭正华，解春雷，李尚健，黄树槐．动态有限元模拟与环轧控制策略，锻压机械，1999，(6)
[34]解春雷，李尚健，黄树槐．辗环过程动力有限元分析中的抱辊约束，锻压机械，1997，(3)
[35]郭正华，解春雷；李尚健．环件热轧动态过程有限元模拟．塑性工程学报，1999，(6)
[36]郭正华，解春雷，李尚健．环件轧制动态过程刚黏塑陛有限元反向模拟．全国锻压学术年会论文，1999
[37]李尚健．金属塑性成形过程模拟．北京：机械工业出版社，1999
[38]蒋友谅．非线性有限元法．北京：北京工业大学出版社，1988
[39]谢水生．王祖唐．金属塑性成形工步的有限元数值模拟．北京：冶金工业出版社，1997
[40]刘相华．刚塑性有限元法及其在轧制中的应用．北京：冶金工业出版社，1994
[41]谢贻权，何福保．弹性和塑性力学中的有限单元法．北京：机械工业出版社，1981
[42]徐次达，华伯浩．固体力学有限元理论、方法及程序．北京：水利电力出版社，1983
[43]庄茁译．连续体和结构体的非线性有限元．北京：清华大学出版社。2002
[44]Ted Belytschko, Wing Kam Liu, Brian Moran. Nonlinear Finite Element
for Continua and Structures.Northwestern University, 1998
[45]Owen D R J, Hinton E. Finite Elements In Plasticity. Pineridge Press Limited Swansea, U.K. 1980
[46]庄茁等译．ABAQUS／Standard有限元软件入门指南．北京：清华大学出版社，1998
[47]庄茁等译．ABAQUS／Explicit有限元软件入门指南．北京：清华大学出版社，1998
[48]Abaqus Analysis User's Manual. ABQUS Corp.,2003
[49]Abaqus/CAE User's Manual. ABQUS Corp.,2003
[50]华林，赵仲治．轧辊变形对环件精度的影响及其补偿．锻压技术，1999，(2)：39—41
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