AZ31镁合金铸轧板材热变形行为及其温热拉深工艺研究
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摘要
传统的镁合金薄板主要采用热轧和挤压方法生产,’其工艺流程长、成材率低、成本高、价格昂贵。因此,采用高效、短流程的铸轧技术来生产高质量的镁合金板坯成为未来镁合金板材生产的一个主流。然而,目前还没有对镁合金铸轧板塑性变形行为进行系统研究以及直接冲压成形性能研究报道。为探索一条铸轧镁合金薄板直接冲压成形的高效、短流程深加工道路,推进镁合金工业发展,本文对铸轧镁合金铸轧板的热塑性成形进行了系统地试验研究与理论分析,并进一步研究了其温热拉深工艺。
铸轧板坯材料中存在高固相率且尺寸细小的半固态组织,其固相颗粒以网络结构与聚合体形式存在,在高温下变形且应变量超过临界应变时,网络结构与聚合体被打破,固相晶粒发生滑动、转动和换位现象。本文针对这一特点,从金属非晶的非牛顿流体粘塑性理论出发,考虑半固态固相颗粒在变形中可以发生滑动、转动和换位,运用混合法则,将铸轧镁合金中滑移、孪生变形结合起来,得到铸轧镁合金的半固态混合流变应力方程。该流变应力模型分为两种情况,当Zener-Hollomon参数Z小于临界值Z0=1.54E11时,高温下滑移是其主导变形机制；当Zener-Hollomon参数Z大于临界值Z0=1.54E11时,即低温下孪生成为主导变形机制。将J.J.Janas (滑移变形机制)经典模型、M.R.Bamett(低温孪晶)应力模型和本模型进行比较,结果表明,在低Z值高温区,J.J.Janas经典模型出现较大的偏差,而本文新模型计算结果与实测结果符合得很好。在高Z值低温区,J.J.Janas经典模型的计算值与实测值偏差进一步扩大,而M.R.Barnett孪晶应力模型和本文新模型都表现了很高的精度,本文新模型的精度略高于M.R.Barnett孪晶应力模型。这说明,半固态混合流变应力模型是合理的,更能反映铸轧镁合金的变形特点。
针对仅根据材料热加工图来制定材料热加工工艺参数得到的工艺笼统、不具体的问题,本文建立了热加工图、有效扩散系数变化图、激活能与变形速率和变形温度的三维变化图,提出了综合以上三种变化图,进行材料热加工工艺最优化的新型分析方法。利用该方法,得到的铸轧镁合金的最佳热加工工艺参数如下：a)变形温度568～603K,变形速率7×10-3～2×10-3s-1之间,适合高温蠕变成形。b)变形温度583～613K,应变速率0.07～0.7s-1,适合锻造、挤压和轧制。c)变形温度538～553K,应变速率0.001～0.002s-1之间,适合温热冲压成形。本文的分析方法同样适合其它金属材料的热加工工艺的制定。
镁合金在高温下变形时,动态再结晶容易产生,造成强烈的软化现象,基于Fields-Backofen材料模型的拉深工艺压边力计算公式不再适用。本文在新流变应力模型的基础上,采用能量法对铸轧镁合金板圆筒件拉深过程压边力公式进行推导,得到了适合铸轧镁合金的防皱最小压边力的工程计算方程。利用该方程计算的应力值在各个温度段都与实测值符合得较好。另外,针对实际生产情况,采用三段式变压边力方法对镁合金板料进行热拉深证明,变压边力可以提高板料的极限拉深比。
针对AZ31B铸轧镁合金板材温热拉深性能差的问题,结合镁合金动态与静态再结晶动力学模型理论,提出了预变形温热拉深工艺。正交实验发现,该工艺中,预变形量成为拉深成形中的主要影响因素；得到最佳工艺参数为：冲头速度45mm/min,预变形量16%,成形温度220℃。对AZ31B铸轧镁合金板材在20-220℃进行预变形温热拉深实验研究发现：预变形使铸轧镁合金板材的拉深性能明显改善,220℃成形可得到极限拉深比LDR=2.26的完整的圆筒件,而未经预变形处理的LDR仅为1.55；使AZ31B铸轧镁合金板材具有最佳拉深性能的冲头温度范围在20-95℃之内；成形温度选择在160～220℃范围内,铸轧镁合金板材具有良好的拉深性能,极限拉深比可达到2.26；随着拉深成形温度的升高,工件中动态再结晶晶粒数量逐渐增加,220℃拉深成形时工件中再结晶晶粒分布趋于均匀。
The conventional magnesium sheets mainly manufactured with the hot-rolling and extrusion, and which have the long flow of process, low efficiency, high cost and price. Recently, as the breach of the process in the twin-roll cast (TRC), the technology of twin-roll cast with high efficiency and short flow process are becoming the mainstream of the manufacture of magnesium sheets. However, the plastic deformation behaviors of TRC-Mg sheets hadn't been systemic research, and there weren't the reports of the study about the direct deep-drawing performance of TRC-Mg sheets. In order to explore a high efficiency and short low process way of the direct deep-drawing TRC-Mg, and boost the industry of magnesium, we investigated the thermo-plasticity deformation behaviors and the process of warm deep-drawing of TRC-Mg sheets.
Since there are fine and high solid fraction semi-solid structure grains in the TRC-Mg sheet, the solid particles constitute a network and aggregation. The construction of network and aggregation will be breakout when the strain up to critical strain during the high temperature deformation, and the phenomena of gliding, wheeling and transposition appear among the solid particles. So we considered that the phenomena of gliding, wheeling and transposition which appear among the solid particles in the hot deformation, based on the non-Newtonian shear viscosity model of amorphous metals, using the mixture law to mix the slid and twin, we got the semi-solid metal mixture flow stress model for the TRC-Mg. The new mixture flow stress model could serve as two conditions. When the Zener-Hollomon parameter (Z) is less than the critical value Zo (1.54E11), the dominant mechanism of TRC-Mg is slip. When the Zener-Hollomon parameter (Z) is higher than the critical value Zo (1.54E11), the dominant mechanism of TRC-Mg is twining. Comparison with the J.J.Jonas (based on the mechanism of slip) and M.R.Barnett (based on the mechanism of twin at low temperature) models indicated that the simulated stress-strain curves calculated by J.J.Jonas model occurred biggish error in the low Z region, and our new mixture model shown fitting the experiment data very well. In the high Z region, the error of calculated by J.J.Jonas model ascended, but M.R.Barnett and the new mixture model also shown the high precision. And the new mixture model was more accurate than M.R.Barnett model. The mentioned above means that the new semi-solid mixture model is reasonable and it can reflect the deformation characteristic of the TRC-Mg.
Generally, the processing map was used to establish the working parameters of the materials. Whereas the working parameters obtained by the processing map is rough. In order to obtain the precise working parameters, the processing map, the effective diffusion coefficient and activation energy map of the alloy were established. Combining the processing map, effective diffusion coefficient and activation energy map obtained the optimum conditions for thermo-mechanical processing. The optimum conditions are as follows:a) At temperature range of 568K to 603K and the strain-rate range from 7×10-3 to 2×10-3S-1. It adapt to the high temperature creep forming. b) At the temperature range of 583K to 613K and the strain-rate range from 0.07 to 0.7 S-1. It adapt to the forging, extrusion and rolling. C) At temperature range of 538K to 553K and the strain-rate range from 0.001 to 0.002S-1. It adapt to the warm deep-drawing. This analysis way is adapted to establish hot working parameters of others metal materials.
The dynamic recrystallization (DRX) can be generated easily during the high temperature deformation for the magnesium alloys. It resulted in the sharp soften phenomena. So the calculating equation of blank holder force (BHF) based on the Fields-Backofen materials model wasn't fit to the deep-drawing of TRC-Mg sheets. In order to optimized control the BHF in the process of deep-drawing cylinder parts, the variable BHF engineering equation of the curve of minimum wrinkles of TRC-Mg sheets was concluded out by the aid of consulting correlative energy conversation theorem, which based on the new flow stress model. The calculated data using the new model fit the tested data very well when the TRC-Mg blank deep-drawing at the temperature from low temperature to high temperature. In addition, according to the practical working-condition, the three segment way of load variable BHF was adopted to the hot deep-drawing of TRC-Mg sheets. The results revealed that limit drawing ratio (LDR) of the TRC-Mg sheets can be improved by loading the variable BHF.
To solve the problem of the poor warm deep drawability of twin-roll cast AZ31B Mg alloy sheet, a warm deep drawing process by utilizing a pre-forming approach which based on the theoretics of dynamic recrystallization (DRX) and static recrystallization was proposed. Orthogonal test design for optimization the working parameters shown that the influence of the pre-forming had become the main factor in the deep-drawing of TRC-Mg sheets. And obtained the optimization working parameters were as follows:punch velocity 45mm/min,strain of pre-forming 16 %,eformation temperature 220℃. The warm deep-drawing experiments of twin-roll cast AZ31B Mg alloy sheets were examined by utilizing a pre-forming approach at temperature range from 20 to 220℃. It is indicated that the deep drawing performance has been significantly improved by utilizing a pre-forming approach. The punch temperature range of 20-95℃was recommended to obtain the best drawability for the twin-roll cast AZ31B Mg alloy sheet. It is found that the twin-roll cast AZ31B Mg alloy sheet was of good deep drawability at forming temperature range of 160-220℃with the higher limit drawing ratio up to 2.26. The dynamic recrystallization (DRX) grains of the workpieces increased gradually with the increase of temperature. And the DRX grains distribution of the materials was more well-distributed, when the workpieces obtained at temperature of 220℃.
铸轧板坯材料中存在高固相率且尺寸细小的半固态组织,其固相颗粒以网络结构与聚合体形式存在,在高温下变形且应变量超过临界应变时,网络结构与聚合体被打破,固相晶粒发生滑动、转动和换位现象。本文针对这一特点,从金属非晶的非牛顿流体粘塑性理论出发,考虑半固态固相颗粒在变形中可以发生滑动、转动和换位,运用混合法则,将铸轧镁合金中滑移、孪生变形结合起来,得到铸轧镁合金的半固态混合流变应力方程。该流变应力模型分为两种情况,当Zener-Hollomon参数Z小于临界值Z0=1.54E11时,高温下滑移是其主导变形机制；当Zener-Hollomon参数Z大于临界值Z0=1.54E11时,即低温下孪生成为主导变形机制。将J.J.Janas (滑移变形机制)经典模型、M.R.Bamett(低温孪晶)应力模型和本模型进行比较,结果表明,在低Z值高温区,J.J.Janas经典模型出现较大的偏差,而本文新模型计算结果与实测结果符合得很好。在高Z值低温区,J.J.Janas经典模型的计算值与实测值偏差进一步扩大,而M.R.Barnett孪晶应力模型和本文新模型都表现了很高的精度,本文新模型的精度略高于M.R.Barnett孪晶应力模型。这说明,半固态混合流变应力模型是合理的,更能反映铸轧镁合金的变形特点。
针对仅根据材料热加工图来制定材料热加工工艺参数得到的工艺笼统、不具体的问题,本文建立了热加工图、有效扩散系数变化图、激活能与变形速率和变形温度的三维变化图,提出了综合以上三种变化图,进行材料热加工工艺最优化的新型分析方法。利用该方法,得到的铸轧镁合金的最佳热加工工艺参数如下：a)变形温度568～603K,变形速率7×10-3～2×10-3s-1之间,适合高温蠕变成形。b)变形温度583～613K,应变速率0.07～0.7s-1,适合锻造、挤压和轧制。c)变形温度538～553K,应变速率0.001～0.002s-1之间,适合温热冲压成形。本文的分析方法同样适合其它金属材料的热加工工艺的制定。
镁合金在高温下变形时,动态再结晶容易产生,造成强烈的软化现象,基于Fields-Backofen材料模型的拉深工艺压边力计算公式不再适用。本文在新流变应力模型的基础上,采用能量法对铸轧镁合金板圆筒件拉深过程压边力公式进行推导,得到了适合铸轧镁合金的防皱最小压边力的工程计算方程。利用该方程计算的应力值在各个温度段都与实测值符合得较好。另外,针对实际生产情况,采用三段式变压边力方法对镁合金板料进行热拉深证明,变压边力可以提高板料的极限拉深比。
针对AZ31B铸轧镁合金板材温热拉深性能差的问题,结合镁合金动态与静态再结晶动力学模型理论,提出了预变形温热拉深工艺。正交实验发现,该工艺中,预变形量成为拉深成形中的主要影响因素；得到最佳工艺参数为：冲头速度45mm/min,预变形量16%,成形温度220℃。对AZ31B铸轧镁合金板材在20-220℃进行预变形温热拉深实验研究发现：预变形使铸轧镁合金板材的拉深性能明显改善,220℃成形可得到极限拉深比LDR=2.26的完整的圆筒件,而未经预变形处理的LDR仅为1.55；使AZ31B铸轧镁合金板材具有最佳拉深性能的冲头温度范围在20-95℃之内；成形温度选择在160～220℃范围内,铸轧镁合金板材具有良好的拉深性能,极限拉深比可达到2.26；随着拉深成形温度的升高,工件中动态再结晶晶粒数量逐渐增加,220℃拉深成形时工件中再结晶晶粒分布趋于均匀。
The conventional magnesium sheets mainly manufactured with the hot-rolling and extrusion, and which have the long flow of process, low efficiency, high cost and price. Recently, as the breach of the process in the twin-roll cast (TRC), the technology of twin-roll cast with high efficiency and short flow process are becoming the mainstream of the manufacture of magnesium sheets. However, the plastic deformation behaviors of TRC-Mg sheets hadn't been systemic research, and there weren't the reports of the study about the direct deep-drawing performance of TRC-Mg sheets. In order to explore a high efficiency and short low process way of the direct deep-drawing TRC-Mg, and boost the industry of magnesium, we investigated the thermo-plasticity deformation behaviors and the process of warm deep-drawing of TRC-Mg sheets.
Since there are fine and high solid fraction semi-solid structure grains in the TRC-Mg sheet, the solid particles constitute a network and aggregation. The construction of network and aggregation will be breakout when the strain up to critical strain during the high temperature deformation, and the phenomena of gliding, wheeling and transposition appear among the solid particles. So we considered that the phenomena of gliding, wheeling and transposition which appear among the solid particles in the hot deformation, based on the non-Newtonian shear viscosity model of amorphous metals, using the mixture law to mix the slid and twin, we got the semi-solid metal mixture flow stress model for the TRC-Mg. The new mixture flow stress model could serve as two conditions. When the Zener-Hollomon parameter (Z) is less than the critical value Zo (1.54E11), the dominant mechanism of TRC-Mg is slip. When the Zener-Hollomon parameter (Z) is higher than the critical value Zo (1.54E11), the dominant mechanism of TRC-Mg is twining. Comparison with the J.J.Jonas (based on the mechanism of slip) and M.R.Barnett (based on the mechanism of twin at low temperature) models indicated that the simulated stress-strain curves calculated by J.J.Jonas model occurred biggish error in the low Z region, and our new mixture model shown fitting the experiment data very well. In the high Z region, the error of calculated by J.J.Jonas model ascended, but M.R.Barnett and the new mixture model also shown the high precision. And the new mixture model was more accurate than M.R.Barnett model. The mentioned above means that the new semi-solid mixture model is reasonable and it can reflect the deformation characteristic of the TRC-Mg.
Generally, the processing map was used to establish the working parameters of the materials. Whereas the working parameters obtained by the processing map is rough. In order to obtain the precise working parameters, the processing map, the effective diffusion coefficient and activation energy map of the alloy were established. Combining the processing map, effective diffusion coefficient and activation energy map obtained the optimum conditions for thermo-mechanical processing. The optimum conditions are as follows:a) At temperature range of 568K to 603K and the strain-rate range from 7×10-3 to 2×10-3S-1. It adapt to the high temperature creep forming. b) At the temperature range of 583K to 613K and the strain-rate range from 0.07 to 0.7 S-1. It adapt to the forging, extrusion and rolling. C) At temperature range of 538K to 553K and the strain-rate range from 0.001 to 0.002S-1. It adapt to the warm deep-drawing. This analysis way is adapted to establish hot working parameters of others metal materials.
The dynamic recrystallization (DRX) can be generated easily during the high temperature deformation for the magnesium alloys. It resulted in the sharp soften phenomena. So the calculating equation of blank holder force (BHF) based on the Fields-Backofen materials model wasn't fit to the deep-drawing of TRC-Mg sheets. In order to optimized control the BHF in the process of deep-drawing cylinder parts, the variable BHF engineering equation of the curve of minimum wrinkles of TRC-Mg sheets was concluded out by the aid of consulting correlative energy conversation theorem, which based on the new flow stress model. The calculated data using the new model fit the tested data very well when the TRC-Mg blank deep-drawing at the temperature from low temperature to high temperature. In addition, according to the practical working-condition, the three segment way of load variable BHF was adopted to the hot deep-drawing of TRC-Mg sheets. The results revealed that limit drawing ratio (LDR) of the TRC-Mg sheets can be improved by loading the variable BHF.
To solve the problem of the poor warm deep drawability of twin-roll cast AZ31B Mg alloy sheet, a warm deep drawing process by utilizing a pre-forming approach which based on the theoretics of dynamic recrystallization (DRX) and static recrystallization was proposed. Orthogonal test design for optimization the working parameters shown that the influence of the pre-forming had become the main factor in the deep-drawing of TRC-Mg sheets. And obtained the optimization working parameters were as follows:punch velocity 45mm/min,strain of pre-forming 16 %,eformation temperature 220℃. The warm deep-drawing experiments of twin-roll cast AZ31B Mg alloy sheets were examined by utilizing a pre-forming approach at temperature range from 20 to 220℃. It is indicated that the deep drawing performance has been significantly improved by utilizing a pre-forming approach. The punch temperature range of 20-95℃was recommended to obtain the best drawability for the twin-roll cast AZ31B Mg alloy sheet. It is found that the twin-roll cast AZ31B Mg alloy sheet was of good deep drawability at forming temperature range of 160-220℃with the higher limit drawing ratio up to 2.26. The dynamic recrystallization (DRX) grains of the workpieces increased gradually with the increase of temperature. And the DRX grains distribution of the materials was more well-distributed, when the workpieces obtained at temperature of 220℃.
引文
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