铝合金板温成形接触和摩擦问题的研究
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摘要
随着能源和环境问题的日益尖锐,全球各大汽车制造商都加快了对车辆轻型化的研发,而车辆轻型化中一个很重要的内容就是车身零件的轻量化。由于铝合金板的强度和钢板相当,而比重只有钢板的1/3,因此已经开始被用来制造汽车覆盖件。铝合金板的塑性差,在常温下难以成形,为了提高铝合金板的成形性能,常常需采用温成形工艺。在铝合金板温成形过程中,摩擦和润滑状态对成形的质量有着重要的影响,对其摩擦和润滑进行研究是目前亟需研究的课题。本文结合通用汽车—中国材料及摩擦学研究联合体资助的研究项目,对铝合金板温成形过程中板料与模具的接触和摩擦进行了理论与实验的研究,建立了板料与模具表面基于分形理论的接触模型和不同润滑状态下的摩擦模型,并对成形过程中不同变形区域的摩擦系数进行了实验测定。
为了研究铝合金板与模具表面的接触摩擦规律,首先必须对其表面形貌有充分的了解。本文利用AF-LI型表面轮廓测量仪对5182铝合金板和模具的表面进行了测量,获得了其表面形貌数据,采用尺度独立的分形参数对板料表面进行了表征,建立了基于分形理论的铝合金板表面形貌模型。基于分形参数所建立的表面形貌模型不受表面轮廓测量仪器分辨率和取样长度的影响,其表征具有唯一性,因而比传统的基于统计分析的模型更为合理。
在表面形貌模型的基础上,建立了铝合金板与模具的弹塑性分形接触模型,该模型将模具视为刚性体,给出了板料与模具接触面的尺寸分布规律和实际接触面积的计算方法,描述了实际接触面积与法向载荷的关系。
摩擦和润滑状态是影响铝合金板温成形的关键因素之一,本文分析了铝合金板在成形过程中的摩擦润滑状态,得出了板料和模具之间处于边界润滑摩擦或混合摩擦状态的结论,并建立了不同润滑条件下的摩擦模型,结合由分形接触模型计算得到的真实接触面积,对不同接触载荷下的摩擦系数进行了理论计算。
在对铝合金板成形过程中的摩擦开展实验研究时,本文针对现有的板料成形摩擦测试方法中存在的实验条件与成形工艺实际状况不一致、测量结果与真实情况偏差大的问题,提出了铝合金板温成形中测量凹、凸模圆角处和拉深筋处摩擦的方法,并设计制作了测试实验装置。在测试实验中,采用了楔形铝合金板试件,在成形中试件受周向压力作用,可较好地模拟板料的实际成形过程,有利于获得更准确的测量结果。
利用自行设计制作的实验装置,对5182铝合金板温成形过程中凹、凸模圆角处和拉深筋处的摩擦系数进行了实验测量,测定了不同的成形区域和成形条件下摩擦系数随凸模行程的变化规律,对理论模型进行了验证。
With the issue of energy and environment becoming increasingly acute,the automobile manufacturers are expediting the development of lightweight vehicles.One of the major tasks in the development of lightweight vehicles is to develop lightweight auto body panels.Aluminum alloy sheet has been applied to produce auto body panels because of its high strength and low specific gravity.However,aluminum alloy sheet is more difficult to form than steel sheet due to its lower plasticity.It is necessary to adopt warm forming process to form aluminum alloy sheet.During the warm forming process, lubrication and friction status are the key factors which influence the forming quality of aluminum alloy sheet.So far,the lubrication and friction status during aluminum alloy sheet warm forming are still the technologies which need further investigation.Supported by Technology Consortium of GM and Chinese Institutes for Materials and Tribology,the author has studied the contact and friction between sheet's and die's surface in aluminum alloy sheet warm forming in both theoretical and experimental approach,and established the contact model based on fractal theory and the friction models for different lubrication status.The friction coefficients in different forming areas are measured by experiments.
In order to study the laws of the contact and friction behavior,the topography data of aluminum alloy sheet surface should be obtained first so that the topography model can be set up.The author obtained the topography data of the aluminum alloy sheet 5182 surface and the die surface by means of AF-LI Synthesis Measuring Profilometer.The surface topography model of aluminum alloy sheet based on fractal theory has been established. The model characterizes and identifies the sheet surface with fractal parameters of scale-independence.The prediction results of topography using fractal based model are not affected by the resolution of measuring instruments and the length of sample.Hence, the model is more reasonable and effective than those based on statistical analysis.
Then,the elastic-plastic contact model between aluminum alloy sheet surface and die surface has been established based on the sheet surface topography model.The contact model,which treats the die as rigid body,gives the laws of the interface's dimension distribution and the calculational formulas of the real contact area under different normal contact loads.
Lubrication and friction status are key factors which influence the forming quality of aluminum alloy sheet during the warm forming process.The author has analysed the lubrication and friction status in different forming areas during aluminum alloy sheet warm forming,and drew the conclusion that the lubrication status between the sheet surface and die surface is boundary lubrication status or mixed lubrication status.The calculational formulas of the friction coefficient are given by the author.Together with the real contact area calculated by the contact model,the friction coefficient under different normal contact loads can be calculated.
In order to test and investigate the dynamic variation of friction in experimental approach,new friction coefficient measurement method and devices have been developed to measure the friction coefficient at punch corner,die corner and drawbead in aluminum alloy sheet warm forming.The method overcomes the disadvantage of existing measurement method.And the feature of the devices is that the real warm forming process of the sheet can be modeled during the measurement.The aluminum alloy sheet sample with wedge-shape is adopted to get the circumferential compressive stress exerted by the cuneal groove.Therefore,more accurate measuring results can be obtained.
Based on the developed experimental systems,the author measured the friction coefficients at punch,die comer and drawbead during aluminum alloy sheet 5182 warm forming.The variation of friction coefficient with the punch's movement is determined. The rationality of the academic models is proved by comparison between the calculated results with the experimental data.
为了研究铝合金板与模具表面的接触摩擦规律,首先必须对其表面形貌有充分的了解。本文利用AF-LI型表面轮廓测量仪对5182铝合金板和模具的表面进行了测量,获得了其表面形貌数据,采用尺度独立的分形参数对板料表面进行了表征,建立了基于分形理论的铝合金板表面形貌模型。基于分形参数所建立的表面形貌模型不受表面轮廓测量仪器分辨率和取样长度的影响,其表征具有唯一性,因而比传统的基于统计分析的模型更为合理。
在表面形貌模型的基础上,建立了铝合金板与模具的弹塑性分形接触模型,该模型将模具视为刚性体,给出了板料与模具接触面的尺寸分布规律和实际接触面积的计算方法,描述了实际接触面积与法向载荷的关系。
摩擦和润滑状态是影响铝合金板温成形的关键因素之一,本文分析了铝合金板在成形过程中的摩擦润滑状态,得出了板料和模具之间处于边界润滑摩擦或混合摩擦状态的结论,并建立了不同润滑条件下的摩擦模型,结合由分形接触模型计算得到的真实接触面积,对不同接触载荷下的摩擦系数进行了理论计算。
在对铝合金板成形过程中的摩擦开展实验研究时,本文针对现有的板料成形摩擦测试方法中存在的实验条件与成形工艺实际状况不一致、测量结果与真实情况偏差大的问题,提出了铝合金板温成形中测量凹、凸模圆角处和拉深筋处摩擦的方法,并设计制作了测试实验装置。在测试实验中,采用了楔形铝合金板试件,在成形中试件受周向压力作用,可较好地模拟板料的实际成形过程,有利于获得更准确的测量结果。
利用自行设计制作的实验装置,对5182铝合金板温成形过程中凹、凸模圆角处和拉深筋处的摩擦系数进行了实验测量,测定了不同的成形区域和成形条件下摩擦系数随凸模行程的变化规律,对理论模型进行了验证。
With the issue of energy and environment becoming increasingly acute,the automobile manufacturers are expediting the development of lightweight vehicles.One of the major tasks in the development of lightweight vehicles is to develop lightweight auto body panels.Aluminum alloy sheet has been applied to produce auto body panels because of its high strength and low specific gravity.However,aluminum alloy sheet is more difficult to form than steel sheet due to its lower plasticity.It is necessary to adopt warm forming process to form aluminum alloy sheet.During the warm forming process, lubrication and friction status are the key factors which influence the forming quality of aluminum alloy sheet.So far,the lubrication and friction status during aluminum alloy sheet warm forming are still the technologies which need further investigation.Supported by Technology Consortium of GM and Chinese Institutes for Materials and Tribology,the author has studied the contact and friction between sheet's and die's surface in aluminum alloy sheet warm forming in both theoretical and experimental approach,and established the contact model based on fractal theory and the friction models for different lubrication status.The friction coefficients in different forming areas are measured by experiments.
In order to study the laws of the contact and friction behavior,the topography data of aluminum alloy sheet surface should be obtained first so that the topography model can be set up.The author obtained the topography data of the aluminum alloy sheet 5182 surface and the die surface by means of AF-LI Synthesis Measuring Profilometer.The surface topography model of aluminum alloy sheet based on fractal theory has been established. The model characterizes and identifies the sheet surface with fractal parameters of scale-independence.The prediction results of topography using fractal based model are not affected by the resolution of measuring instruments and the length of sample.Hence, the model is more reasonable and effective than those based on statistical analysis.
Then,the elastic-plastic contact model between aluminum alloy sheet surface and die surface has been established based on the sheet surface topography model.The contact model,which treats the die as rigid body,gives the laws of the interface's dimension distribution and the calculational formulas of the real contact area under different normal contact loads.
Lubrication and friction status are key factors which influence the forming quality of aluminum alloy sheet during the warm forming process.The author has analysed the lubrication and friction status in different forming areas during aluminum alloy sheet warm forming,and drew the conclusion that the lubrication status between the sheet surface and die surface is boundary lubrication status or mixed lubrication status.The calculational formulas of the friction coefficient are given by the author.Together with the real contact area calculated by the contact model,the friction coefficient under different normal contact loads can be calculated.
In order to test and investigate the dynamic variation of friction in experimental approach,new friction coefficient measurement method and devices have been developed to measure the friction coefficient at punch corner,die corner and drawbead in aluminum alloy sheet warm forming.The method overcomes the disadvantage of existing measurement method.And the feature of the devices is that the real warm forming process of the sheet can be modeled during the measurement.The aluminum alloy sheet sample with wedge-shape is adopted to get the circumferential compressive stress exerted by the cuneal groove.Therefore,more accurate measuring results can be obtained.
Based on the developed experimental systems,the author measured the friction coefficients at punch,die comer and drawbead during aluminum alloy sheet 5182 warm forming.The variation of friction coefficient with the punch's movement is determined. The rationality of the academic models is proved by comparison between the calculated results with the experimental data.
引文
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