基于CAE技术的铝型材挤压模具疲劳寿命仿真分析
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摘要
随着中国经济建设的高速发展,建筑铝型材和工业铝型材得到广泛的应用。挤压模具对铝型材挤压生产非常重要,消耗量很大,模具的成本占挤压生产成本的30%-40%。研究和生产实践证明,疲劳破坏是挤压模具失效的主要原因之一,因此开展疲劳研究有着重要意义。在产品设计阶段采用有限元计算机模拟仿真技术可对模具失效和寿命问题进行广泛而深入的研究。
本文阐述了疲劳分析及挤压模具设计的研究现状,运用铝型材挤压模具的设计理论及经验,结合铝型材挤压设备性能参数,设计出平面分流模具基本结构尺寸,并以UG为工具初步生成挤压模具的三维模型。进而在有限元法以及疲劳分析的理论基础上建立挤压模具的有限元模型,运用有限元分析MSC.Patran/Nastran软件进行了静强度分析,得到型材模具的应力分布状况。根据挤压模具的工作特点确定运用全寿命疲劳理论的方法对其进行疲劳分析,在分析过程中根据挤压过程中挤压载荷的变化运用MSC.Fatigue软件生成了挤压载荷曲线,根据模具材料4Cr5MoSiV1的相关力学性能参数生成了分析所需的S-N曲线,为模具的疲劳寿命分析做好了准备。最后以模具的静应力分析结果为基础,运用有限元分析软件MSC.Fatigue对挤压模具疲劳寿命进行了预估。
模具寿命分析结果显示出:在挤压生产过程中,全挤压力的各个分量对模具各结构部位产生的疲劳破坏作用是不相同的,本模具的薄弱部位在工作带处。这一疲劳分析结果对进一步进行模具优化设计具有一定的指导意义。
With the rigid development of economics, the extrusion profiled aluminum product is widely applied in architecture and industry. The extrusion die is the most important tool in extrusion profiled aluminum production, and is also consumed vastly. The cost of extrusion die is about 30% -40% of the total production cost. It is proved by research and practice that fatigue is one of major cause of extrusion die failure. So research in fatigue is significant to extrusion die design. By using finite element method and computer aided analysis, fatigue destroy research becomes deeper and wider.
This paper firstly discussed current research in fatigue analysis and extrusion die design, worked out the primary dimension of the extrusion die according to design theory and experience and set up three dimension model of extrusion die under UG tools. Then by combining the methods of finite element and fatigue analysis, stress distributing status of extrusion die and static intensity was acquired under MSC.Patran/Nastran software. According to extrusion die work, full life fatigue analysis method was chosen. Extrusion load curve was created under MSC.Fatigue along with variety of extrusion load in extrusion process. S-N curve of 4Cr5MoSiV1 was created according to related material parameters and provided for die fatigue life analysis. Finally based on results of static stress analysis, extrusion die fatigue life was estimated beforehand by using MSC.Fatigue.
In results of extrusion die fatigue life analysis, it showed that fatigue destroy effects caused by every vector of extrusion stress in different structure part is different and the weakness part is located in work structure. The results are guided to improve the optimization of extrusion die design in certain sense.
本文阐述了疲劳分析及挤压模具设计的研究现状,运用铝型材挤压模具的设计理论及经验,结合铝型材挤压设备性能参数,设计出平面分流模具基本结构尺寸,并以UG为工具初步生成挤压模具的三维模型。进而在有限元法以及疲劳分析的理论基础上建立挤压模具的有限元模型,运用有限元分析MSC.Patran/Nastran软件进行了静强度分析,得到型材模具的应力分布状况。根据挤压模具的工作特点确定运用全寿命疲劳理论的方法对其进行疲劳分析,在分析过程中根据挤压过程中挤压载荷的变化运用MSC.Fatigue软件生成了挤压载荷曲线,根据模具材料4Cr5MoSiV1的相关力学性能参数生成了分析所需的S-N曲线,为模具的疲劳寿命分析做好了准备。最后以模具的静应力分析结果为基础,运用有限元分析软件MSC.Fatigue对挤压模具疲劳寿命进行了预估。
模具寿命分析结果显示出:在挤压生产过程中,全挤压力的各个分量对模具各结构部位产生的疲劳破坏作用是不相同的,本模具的薄弱部位在工作带处。这一疲劳分析结果对进一步进行模具优化设计具有一定的指导意义。
With the rigid development of economics, the extrusion profiled aluminum product is widely applied in architecture and industry. The extrusion die is the most important tool in extrusion profiled aluminum production, and is also consumed vastly. The cost of extrusion die is about 30% -40% of the total production cost. It is proved by research and practice that fatigue is one of major cause of extrusion die failure. So research in fatigue is significant to extrusion die design. By using finite element method and computer aided analysis, fatigue destroy research becomes deeper and wider.
This paper firstly discussed current research in fatigue analysis and extrusion die design, worked out the primary dimension of the extrusion die according to design theory and experience and set up three dimension model of extrusion die under UG tools. Then by combining the methods of finite element and fatigue analysis, stress distributing status of extrusion die and static intensity was acquired under MSC.Patran/Nastran software. According to extrusion die work, full life fatigue analysis method was chosen. Extrusion load curve was created under MSC.Fatigue along with variety of extrusion load in extrusion process. S-N curve of 4Cr5MoSiV1 was created according to related material parameters and provided for die fatigue life analysis. Finally based on results of static stress analysis, extrusion die fatigue life was estimated beforehand by using MSC.Fatigue.
In results of extrusion die fatigue life analysis, it showed that fatigue destroy effects caused by every vector of extrusion stress in different structure part is different and the weakness part is located in work structure. The results are guided to improve the optimization of extrusion die design in certain sense.
引文
[1]刘静安.铝型材挤压模具设计、制造、使用及维修.北京:冶金工业出版社,2002
[2]刘建生,陈慧琴,郭晓霞.金属塑性加工有限元模拟技术与应用.北京:冶金工业出版社,2003
[3]郝滨海.挤压模具简明设计手册.北京:化学工业出版社,2006
[4]马怀宪.金属塑性加工学—挤压、拉拔与管材冷轧.北京:冶金工业出版社,2006
[5] [英]F.V.沃诺克P.P.本哈姆.固体力学与材料强度.北京:人民教育出版社,1982
[6]张永昌. MSC.Nastran有限元分析理论基础与应用.北京:科学出版社,2004
[7]刘静安,谢建新.大型铝合金型材挤压技术与工模具优化设计.北京:冶金工业出版社,2003
[8]马健哲.铝型材挤压分流模具交互式3DCAD/CAE设计技术开发:[中南大学硕士学位论文].长沙:中南大学,2002
[9]叶南海.挤压分流模具三维结构建模及其软件系统开发:[中南大学硕士学位论文].长沙:中南大学,2003
[10]陈泽中.铝型材挤压CAD/CAE/CAO技术研究:[南昌大学博士学位论文].南昌:南昌大学,2002
[11]杨朝丽.计算机辅助工程(CAE)发展现状及其应用综述.昆明大学学报,2003,42(2):32-36
[12]杨海成,廖文和.基于知识的三维CAD技术及应用.北京:科学出版社,2005
[13]李名尧.模具CAD/CAM.北京:机械工业出版社,2004
[14]叶南海.UGNX5.0模具设计基础与应用提高.北京:国防工业出版社,2008
[15]曾珊琪,丁毅.模具寿命与失效.北京:化学工业出版社,2005
[16]刘惟信.机械可靠性设计.北京:清华大学出版社,1995
[17]李舜酩.机械疲劳与可靠性设计.北京:科学技术出版社,2006
[18]褚武扬.断裂力学基础.北京:科学出版社,1979
[19]吴富民.结构疲劳强度.西安:西北工业大学出版社,1985
[20]赵少汴,王忠宝.抗疲劳数据——方法与数据.北京:机械工业出版社,1985
[21]赵云路,刘静安.空心铝型材挤压模具优化设计(2).轻合金加工技术,1997,25(8):38-44
[22]魏军.金属挤压机.北京:化学工业出版社,2005
[23]姜立民.基于数值模拟的铝型材挤压模工作带优化设计:[上海交通大学硕士学位论文].上海:上海交通大学,2000
[24]黄翔,李迎光.UG应用开发教程与实例精解.北京:清华大学出版社,2005
[25]徐芝纶.弹性力学简明教程.北京:高等教育出版社.2002
[26]刘国庆,杨庆东.ANSYS工程应用教程(机械篇).北京:中国铁道出版社,2003
[27] Gouri Dhatt, Gilbert and Touzot.The Finite Element Method Displayed.New York:John Wiley & Sons,1984
[28] G.R.Liu S.S.Quek著,龙述尧,侯淑娟,钱长照译.有限元法实用教程.长沙:湖南大学出版社.2004
[29]Jonathan Wickert.An Introduction to Mechanical Engineering.西安:西安交通大学出版社,2003
[30]马爱军,周传月,王旭.Patran和Nastran有限元分析(专业教程).北京:清华大学出版社,2006
[31]梁尚明,殷国富.现代机械优化设计方法.北京:化学工业出版社,2005
[32]李邦国,路化鹏,胡仁喜等.Patran2006与Nastran2007有限元分析实例指导教程.北京:机械工业出版社,2008
[33]孙长任,杜家政,卢绪智等.MSC.Nastran应用实例教程.北京:科学出版社,2005
[34]温诗铸,黎明.机械学发展战略研究.北京:清华大学出版社,2003
[35]周传月,郑红霞,罗慧强.MSCFatigue疲劳分析应用与实例.北京:科学出版社,2005
[36]赵永祥.应变疲劳可靠性分析的现状与展望.机械工程学报,2001,17(11):1-6
[37] [苏]M.B.斯德洛日夫E.A.波波夫.金属压力加工原理.北京:机械工业出版社,1980
[38] Anupam Saxena,Birendra Sahay.Computer Aided Engineering Design.New Delhi India:Anamaya Publishers,2005
[39] Suresh S著,王光中等译.材料的疲劳.北京:国防工业出版社,1996
[40]王坤.大型汽轮机转子寿命问题研究:[华中科技大学博士学位论文].武汉:华中科技大学,2004
[41]Welo T, Smabrekke A.Two-dimensional simulation of porthole extrusion [M] .Aluminium,1995,23(9):87-90
[42]Lijianchao.FEM Simulation of Bending Formability for Laminate Steel/Resin/Steel Lightweight Composite Sheet[J] .Journal of Materials Science & Technology,2004,41(2):31-34
[43]陈再之,兰德年.模具钢手册.北京:冶金工业出版社.2003
[2]刘建生,陈慧琴,郭晓霞.金属塑性加工有限元模拟技术与应用.北京:冶金工业出版社,2003
[3]郝滨海.挤压模具简明设计手册.北京:化学工业出版社,2006
[4]马怀宪.金属塑性加工学—挤压、拉拔与管材冷轧.北京:冶金工业出版社,2006
[5] [英]F.V.沃诺克P.P.本哈姆.固体力学与材料强度.北京:人民教育出版社,1982
[6]张永昌. MSC.Nastran有限元分析理论基础与应用.北京:科学出版社,2004
[7]刘静安,谢建新.大型铝合金型材挤压技术与工模具优化设计.北京:冶金工业出版社,2003
[8]马健哲.铝型材挤压分流模具交互式3DCAD/CAE设计技术开发:[中南大学硕士学位论文].长沙:中南大学,2002
[9]叶南海.挤压分流模具三维结构建模及其软件系统开发:[中南大学硕士学位论文].长沙:中南大学,2003
[10]陈泽中.铝型材挤压CAD/CAE/CAO技术研究:[南昌大学博士学位论文].南昌:南昌大学,2002
[11]杨朝丽.计算机辅助工程(CAE)发展现状及其应用综述.昆明大学学报,2003,42(2):32-36
[12]杨海成,廖文和.基于知识的三维CAD技术及应用.北京:科学出版社,2005
[13]李名尧.模具CAD/CAM.北京:机械工业出版社,2004
[14]叶南海.UGNX5.0模具设计基础与应用提高.北京:国防工业出版社,2008
[15]曾珊琪,丁毅.模具寿命与失效.北京:化学工业出版社,2005
[16]刘惟信.机械可靠性设计.北京:清华大学出版社,1995
[17]李舜酩.机械疲劳与可靠性设计.北京:科学技术出版社,2006
[18]褚武扬.断裂力学基础.北京:科学出版社,1979
[19]吴富民.结构疲劳强度.西安:西北工业大学出版社,1985
[20]赵少汴,王忠宝.抗疲劳数据——方法与数据.北京:机械工业出版社,1985
[21]赵云路,刘静安.空心铝型材挤压模具优化设计(2).轻合金加工技术,1997,25(8):38-44
[22]魏军.金属挤压机.北京:化学工业出版社,2005
[23]姜立民.基于数值模拟的铝型材挤压模工作带优化设计:[上海交通大学硕士学位论文].上海:上海交通大学,2000
[24]黄翔,李迎光.UG应用开发教程与实例精解.北京:清华大学出版社,2005
[25]徐芝纶.弹性力学简明教程.北京:高等教育出版社.2002
[26]刘国庆,杨庆东.ANSYS工程应用教程(机械篇).北京:中国铁道出版社,2003
[27] Gouri Dhatt, Gilbert and Touzot.The Finite Element Method Displayed.New York:John Wiley & Sons,1984
[28] G.R.Liu S.S.Quek著,龙述尧,侯淑娟,钱长照译.有限元法实用教程.长沙:湖南大学出版社.2004
[29]Jonathan Wickert.An Introduction to Mechanical Engineering.西安:西安交通大学出版社,2003
[30]马爱军,周传月,王旭.Patran和Nastran有限元分析(专业教程).北京:清华大学出版社,2006
[31]梁尚明,殷国富.现代机械优化设计方法.北京:化学工业出版社,2005
[32]李邦国,路化鹏,胡仁喜等.Patran2006与Nastran2007有限元分析实例指导教程.北京:机械工业出版社,2008
[33]孙长任,杜家政,卢绪智等.MSC.Nastran应用实例教程.北京:科学出版社,2005
[34]温诗铸,黎明.机械学发展战略研究.北京:清华大学出版社,2003
[35]周传月,郑红霞,罗慧强.MSCFatigue疲劳分析应用与实例.北京:科学出版社,2005
[36]赵永祥.应变疲劳可靠性分析的现状与展望.机械工程学报,2001,17(11):1-6
[37] [苏]M.B.斯德洛日夫E.A.波波夫.金属压力加工原理.北京:机械工业出版社,1980
[38] Anupam Saxena,Birendra Sahay.Computer Aided Engineering Design.New Delhi India:Anamaya Publishers,2005
[39] Suresh S著,王光中等译.材料的疲劳.北京:国防工业出版社,1996
[40]王坤.大型汽轮机转子寿命问题研究:[华中科技大学博士学位论文].武汉:华中科技大学,2004
[41]Welo T, Smabrekke A.Two-dimensional simulation of porthole extrusion [M] .Aluminium,1995,23(9):87-90
[42]Lijianchao.FEM Simulation of Bending Formability for Laminate Steel/Resin/Steel Lightweight Composite Sheet[J] .Journal of Materials Science & Technology,2004,41(2):31-34
[43]陈再之,兰德年.模具钢手册.北京:冶金工业出版社.2003