盘形件局部加热旋压增厚过程设计
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摘要
针对薄辐板厚轮缘盘形件提出一种局部加热旋压增厚成形方法。通过数学建模,得到了变形前沿即加热热源位置随时间变化的规律并给出了相应的加热功率,计算结果表明,在增厚过程中火焰喷枪近似匀速向圆板中心推进,在历经不同温度分区时,需要施以不同功率才能使变形前沿温度达到目标温度。以半径191 mm、厚度2.5 mm的圆形板料为例进行工艺实验,实验中,旋轮沿径向向内进给压缩轮缘的同时,火焰随着变形区前沿的变化而向内移动。实验结果表明,局部加热能使工件心部支撑材料保持足够的刚度抵抗失稳的产生,单道次增厚比可以达到2以上,与冷旋相比,能显著提高增厚效率。
A local-heating rotary thickening process was proposed for the forming of disc-like blanks with thin plate and thick rim. Based on mathematical modeling,the variation regularity of deformation frontier,i. e.,heat source over time was acquired,with corresponding heating power calculated. The calculated results show that the heaters should move towards the blank center in an approximate constant speed and the heating power should be timely adjusted to make sure the target temperature of the deformation front. Disc-like blanks with191 mm in radius and 2. 5 mm in thickness were used in experiments to validate the process design. In which,the rim was compressed by the roller in radial direction,meanwhile,the heater moved towards the blank center following the deformation front. The experiments results show that the center portion of the blank can provide adequate stiffness to overcome the buckling,the single-pass thickening ratio can reach a value over 2,and the thickening efficiency is significantly improved compared to that of the cold rotary forming.
A local-heating rotary thickening process was proposed for the forming of disc-like blanks with thin plate and thick rim. Based on mathematical modeling,the variation regularity of deformation frontier,i. e.,heat source over time was acquired,with corresponding heating power calculated. The calculated results show that the heaters should move towards the blank center in an approximate constant speed and the heating power should be timely adjusted to make sure the target temperature of the deformation front. Disc-like blanks with191 mm in radius and 2. 5 mm in thickness were used in experiments to validate the process design. In which,the rim was compressed by the roller in radial direction,meanwhile,the heater moved towards the blank center following the deformation front. The experiments results show that the center portion of the blank can provide adequate stiffness to overcome the buckling,the single-pass thickening ratio can reach a value over 2,and the thickening efficiency is significantly improved compared to that of the cold rotary forming.
引文
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[11]李国和,王敏杰.淬硬45钢在高温、高应变率下的动态力学性能及本构关系[J].爆炸与冲击,2010,30(4):433-438.LI Guohe,WANG Minjie.Dynamic mechanical properties and constitutive relationship of hardened steel(45HRC)under high temperature and high strain rate[11].Explosion and Shock Waves,2010,30(4):433-438.
[2]李小曼,桂艳.齿轮旋压制造技术的研究现状及发展[J].机械研究与应用,2009,(3):14-15,21.LI Xiaoman,GUI Yan.Research on the development of gear technology by spinning[J].Mechanical Research&Application,2009,(3):14-15,21.
[3]宛琼,李付国,李超玲.筒形件强力旋压的有限元模拟[J].锻压装备与制造技术,2011,(4):83-85.WAN Qiong,LI Fuguo,LI Chaoling.Numerical simulation on power spinning process of cylindrical workpiece based on FEM[J].China Metalforming Equipment&Manufacturing Technology,2011,(4):83-85.
[4]夏琴香.三维非轴对称零件旋压成形机理研究[J].机械工程学报,2004,40(2):153-156.XIA Qinxiang.Investigation on the mechanism of the spinning technology of the 3D non-axisymmetric parts[J].Chinese Journal of Mechanical Engineering,2004,40(2):153-156.
[5]黄亮,杨合,詹梅,等.旋轮参数对铝合金分形旋压的影响规律[J].塑性工程学报,2009,16(2):85-89.HUANG Liang,YAGN He,ZHAN Mei,et al.Research on influences of roller parameters on splitting spinning of aluminum alloy[J].Journal of Plasticity Engineering,2009,16(2):85-89.
[6]赵立杰,郑强,聂均,等.发动机前端附件带轮旋压成形仿真[J].塑性工程学报,2015,22(2):30-36.ZHAO Lijie,ZHENG Qiang,NIE Jun,et al.Simulation analysis on spin forming of pulleys for engine front end accessory[J].Journal of Plasticity Engineering,2015,22(2):30-36.
[7]金俊松,夏巨谌,王新云,等.板料旋压增厚新工艺[C]//第四届全球华人塑性加工技术研讨会论集.重庆,2011:56-58.JIN Junsong,XIA Juchen,WANG Xinyun,et al.Thickening process for sheet metal by spinning[C]//Proceeding of the 4th Ethnic Chinese Conference on Plastic Forming Technology.Chongqing,2011:56-58.
[8]WANG Xinyun,LI Lan,DENG Lei,et al.Effect of forming parameters on sheet metal stability during a rotary forming process for rim thickening[J].Journal of Materials Processing Technology,2015,223:262-273.
[9]HEMMATI S J,SHIN J G.Estimation of flame parameters for flame bending process[J].International Journal of Machine Tools and Manufacture,2007,47(5):799-804.
[10]江俊志,戴虹,周世恒.基于高斯热源的钢轨气压焊火焰加热温度场数值模拟及加热器优化设计[J].电焊机,2014,44(1):9-14.JIANG Junzhi,DAI Hong,ZHOU Shiheng.Numerical simulation on temperature field of flame heating process of rail gas pressure welding and optimization design of heater based on Gaussian heat source[J].Electric Welding Machine,2014,44(1):9-14.
[11]李国和,王敏杰.淬硬45钢在高温、高应变率下的动态力学性能及本构关系[J].爆炸与冲击,2010,30(4):433-438.LI Guohe,WANG Minjie.Dynamic mechanical properties and constitutive relationship of hardened steel(45HRC)under high temperature and high strain rate[11].Explosion and Shock Waves,2010,30(4):433-438.