转向油泵定子成形工艺研究及实验验证
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摘要
转向油泵定子是传动系统的重要零件。由于转向油泵定子的内部形状复杂，零件壁厚分布不均，金属流动规律难于掌握，目前人们对这种非均匀壁厚锻件的温挤压成形工艺研究几乎没有，其成形工艺及生产用模具结构并未达到最优化。
本论文采用先进的数值分析方法——有限元法，结合金属在温挤压成形过程的具体特点，详细论述了三维问题的刚粘塑性有限元法，介绍了金属塑性成形过程的分析方法，以及刚-粘塑性有限元法的基本理论，建立了刚-粘塑性模形，推导了基于Lagrange乘子法和过应力模形的刚粘塑性有限元列式，并对转向油泵定子的成形工艺过程进行了研究分析。
本课题根据上述理论，利用有限元数值模拟仿真软件DEFORM-3D，对转向油泵定子温挤成形工艺过程进行模拟仿真分析，优化了油泵定子的成形工艺及模具参数。论文具体分析研究了不同成形工艺过程中金属流动的特点，并对不同凸模行程下温挤成形过程中的金属流动特点、坯料连皮厚度(底部高度)与温挤压成形工艺中的轴向界限尺寸的差值对金属变形阶段的影响进行了分析，获得了坯料在不同凸模行程下的等效应变场、速度场等场变量及凸模行程-载荷曲线，同时对油泵定子成形过程的影响因素等进行了分析，优化并获得了合理的温挤成形工艺及模具参数。最后，利用模拟优化获得的各项工艺参数进行生产实验，得到实际生产出的合格油泵定子件，并将模拟结果与生产实验结果进行比较。
通过本课题的研究，解决了油泵定子在工程实际中存在的问题，利用本论文的研究成果可以生产出符合厂家要求的合格的油泵定子零件。同时，本论文的研究成果对非均匀壁厚锻件的温挤压成形工艺研究有重要的指导意义及实用价值。
Sway oil pump stator is an important part of the drive system. The inside fashion of the sway oil pump stator is complex, its wall thickness is pockety and the metal flow law is difficult to master. At the present time, the investigation of warm extrusion forming technique for the nonuniform wall thickness forging has few to been done. The forming technique and die configuration which use for production have not achieve optimization.
In this article, we introducte the advanced numerical,analysis method-finite element method and lucubrate the rigid-viscoplasticity basic theory for three-dimensional problem with the metal's specific feature of the warm extrusion forming process, the analytical procedure of metal ductility forming process and the rigid- viscoplasticity finite element method'basic theory. The rigid-viscoplasticity's modle has been made and the rigid-viscoplasticity's modle finite element columnwise based on the Lagrange facil method and overtension overtress has been deducted in this paper. At the same time ,we have analytic studied the forming technique process for the sway oil pump stator.
According to the above theories, with using the software-DEFORM-3D ,we have made the numerical analog simulation and analyse the warm extrusion forming technique process for sway oil pump stator, optimized the forming :technique and the die parameter for the pockety wall thickness forging This paper concretely analysis and research metal flow's characterize in different forming processes. In different in terne die travel, the metal flow characterize in warm extrusion forming processes and the affection for the flow of metal stage which made by the difference between the blank bottom altitude and the axial direction limiting size in warm extrusion forming technique have been analysed We have gotten the equivalent strain field and the velocity field and other field variable that the blank in different in terne die travel and the die travel- load curve..At the same time ,we have analyzed the contributing factor for the oil pump stator forming process optimized and achieve thereasonable die parameter for the war
m extrusion forming Finally, the optimized technics parameters were used into pilot production, then the qualified oil pump stator forging were produced, the analog results were compared with those of pilot production.
Through the study of this problem, the sway oil pump stator 's problem that exsits
in actual engineering was resolved, using the research conclusion of this paper, we could produce oil pump stator that meet the factory's require. At the same time , in the field of warm extrusion forming technique for pockety wall thickness forging,the research conclusion of this paper has important leading meaning and application value.
本论文采用先进的数值分析方法——有限元法，结合金属在温挤压成形过程的具体特点，详细论述了三维问题的刚粘塑性有限元法，介绍了金属塑性成形过程的分析方法，以及刚-粘塑性有限元法的基本理论，建立了刚-粘塑性模形，推导了基于Lagrange乘子法和过应力模形的刚粘塑性有限元列式，并对转向油泵定子的成形工艺过程进行了研究分析。
本课题根据上述理论，利用有限元数值模拟仿真软件DEFORM-3D，对转向油泵定子温挤成形工艺过程进行模拟仿真分析，优化了油泵定子的成形工艺及模具参数。论文具体分析研究了不同成形工艺过程中金属流动的特点，并对不同凸模行程下温挤成形过程中的金属流动特点、坯料连皮厚度(底部高度)与温挤压成形工艺中的轴向界限尺寸的差值对金属变形阶段的影响进行了分析，获得了坯料在不同凸模行程下的等效应变场、速度场等场变量及凸模行程-载荷曲线，同时对油泵定子成形过程的影响因素等进行了分析，优化并获得了合理的温挤成形工艺及模具参数。最后，利用模拟优化获得的各项工艺参数进行生产实验，得到实际生产出的合格油泵定子件，并将模拟结果与生产实验结果进行比较。
通过本课题的研究，解决了油泵定子在工程实际中存在的问题，利用本论文的研究成果可以生产出符合厂家要求的合格的油泵定子零件。同时，本论文的研究成果对非均匀壁厚锻件的温挤压成形工艺研究有重要的指导意义及实用价值。
Sway oil pump stator is an important part of the drive system. The inside fashion of the sway oil pump stator is complex, its wall thickness is pockety and the metal flow law is difficult to master. At the present time, the investigation of warm extrusion forming technique for the nonuniform wall thickness forging has few to been done. The forming technique and die configuration which use for production have not achieve optimization.
In this article, we introducte the advanced numerical,analysis method-finite element method and lucubrate the rigid-viscoplasticity basic theory for three-dimensional problem with the metal's specific feature of the warm extrusion forming process, the analytical procedure of metal ductility forming process and the rigid- viscoplasticity finite element method'basic theory. The rigid-viscoplasticity's modle has been made and the rigid-viscoplasticity's modle finite element columnwise based on the Lagrange facil method and overtension overtress has been deducted in this paper. At the same time ,we have analytic studied the forming technique process for the sway oil pump stator.
According to the above theories, with using the software-DEFORM-3D ,we have made the numerical analog simulation and analyse the warm extrusion forming technique process for sway oil pump stator, optimized the forming :technique and the die parameter for the pockety wall thickness forging This paper concretely analysis and research metal flow's characterize in different forming processes. In different in terne die travel, the metal flow characterize in warm extrusion forming processes and the affection for the flow of metal stage which made by the difference between the blank bottom altitude and the axial direction limiting size in warm extrusion forming technique have been analysed We have gotten the equivalent strain field and the velocity field and other field variable that the blank in different in terne die travel and the die travel- load curve..At the same time ,we have analyzed the contributing factor for the oil pump stator forming process optimized and achieve thereasonable die parameter for the war
m extrusion forming Finally, the optimized technics parameters were used into pilot production, then the qualified oil pump stator forging were produced, the analog results were compared with those of pilot production.
Through the study of this problem, the sway oil pump stator 's problem that exsits
in actual engineering was resolved, using the research conclusion of this paper, we could produce oil pump stator that meet the factory's require. At the same time , in the field of warm extrusion forming technique for pockety wall thickness forging,the research conclusion of this paper has important leading meaning and application value.
引文
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