单点增量成形U型金属波纹管的试验研究
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摘要
分析了工业领域中塑性成形管件加工的工艺制造需求和研究现状,介绍了单点增量成形金属波纹管的工作原理。为获得工艺参数对成形过程及成形质量的影响规律,建立了基于Abaqus/Explicit的U型金属波纹管单点增量成形有限元模型,搭建实验平台,开展了试验研究。针对T3紫铜材料,通过不同加工工艺参数下的试验,以波纹成形高度为成形质量检测指标,获得了单点增量加工过程中层间距、主轴转速、轴向进给速度对加工结果的影响规律。结果表明,主轴转速对金属波纹管成形波纹高度影响最大,其次为层间距,而轴向进给速度对成形质量影响不显著。在主轴转速为450 r/min,层间距为0.25 mm,轴向进给速度为0.2 mm/r时为最优工艺参数,金属波纹管单点增量成形质量好、精度高。通过仿真和试验结果对比,验证了此优化结果的可靠性。为进一步应用该工艺提供了参考。
The manufacturing requirements and research status of plastic forming pipe fittings in the industrial field are analyzed. The working principle of single point incremental forming metal bellows is introduced. In order to obtain the influence of process parameters on the forming process and forming quality, the finite element model of U-shaped metal bellows of single point incremental forming was established by the finite element analysis software ABAQUS/Explicit. The experimental platform was built and the experimental research was carried out. The T3 red copper was selected as material, through the experiments under different processing parameters, the corrugated forming height is used as the forming quality testing index, and the effect of the interlayer space, spindle speed and axial feed speed on the processing results in the process of single point incremental machining is obtained. The results show that the spindle speed has the greatest impact on the corrugated height of the metal bellows, followed by the interlayer space, and the axial feed speed has no significant influence on the forming quality. The single point incremental forming of metal bellows is of good quality and high precision when the spindle speed is 450 r/min and the interlayer space is 0.25 mm axial feed speed of 0.2 mm/r. The reliability of the optimization results is verified by simulation and experimental results. It provides a reference for the further application of the process.
The manufacturing requirements and research status of plastic forming pipe fittings in the industrial field are analyzed. The working principle of single point incremental forming metal bellows is introduced. In order to obtain the influence of process parameters on the forming process and forming quality, the finite element model of U-shaped metal bellows of single point incremental forming was established by the finite element analysis software ABAQUS/Explicit. The experimental platform was built and the experimental research was carried out. The T3 red copper was selected as material, through the experiments under different processing parameters, the corrugated forming height is used as the forming quality testing index, and the effect of the interlayer space, spindle speed and axial feed speed on the processing results in the process of single point incremental machining is obtained. The results show that the spindle speed has the greatest impact on the corrugated height of the metal bellows, followed by the interlayer space, and the axial feed speed has no significant influence on the forming quality. The single point incremental forming of metal bellows is of good quality and high precision when the spindle speed is 450 r/min and the interlayer space is 0.25 mm axial feed speed of 0.2 mm/r. The reliability of the optimization results is verified by simulation and experimental results. It provides a reference for the further application of the process.
引文
[1] Aleksander K. Belyaev, Tatiana V. Zinovieva, Kirill K. Smirnov. Theoretical and experimental studies of the stress-strain state of expansion bellows as elastic shells [J]. St. Petersburg Poly technical University Journal: Physics and Mathematics, 2017, 3(1):7-14.
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[3] 王焕庆. 压力容器与换热器膨胀节选用指南.第3册.Vol.3,HTZ-3型膨胀节整体成形加强U形系列基本参数与尺寸,HTZ-3 type[M]. 合肥:合肥工业大学出版社, 2012:78-84.WANG HuanQing. Selection Guide for pressure vessel and heat exchanger expansion joint. Third.Vol.3, HTZ-3 expansion joint integral forming to strengthen the U shape series basic parameters and dimensions, HTZ-3 type[M]. HeFei:HeFei University of Technology Press, 2012:78-84(In Chinese).
[4] Alves L M, Martins P A F. Forming of thin-walled tubes into toroidal shells[J]. Journal of Materials Processing Tech, 2010, 210(4):689-695.
[5] Alves M L, Almeida B P P, Rosa P A R, et al. End forming of thin-walled tubes[J]. Journal of Materials Processing Technology, 2006, 177(1-3):183-187.
[6] Almeida B P P, Alves M L, Rosa P A R, et al. Expansion and reduction of thin-walled tubes using a die: Experimental and theoretical investigation[J]. International Journal of Machine Tools & Manufacture, 2006, 46(12):1643-1652.
[7] Park T D, Kyriakides S. On the collapse of dented cylinders under external pressure[J]. International Journal of Mechanical Sciences, 2015, 38(5):557-578.
[8] Niknejad A, Moeinifard M. Theoretical and experimental studies of the external inversion process in the circular metal tubes[J]. Materials & Design, 2012, 40(9):324-330.
[9] Miller J E, Kyriakides S, Bastard A H. On bend-stretch forming of aluminum extruded tubes - I: Experiments[J]. International Journal of Mechanical Sciences, 2015, 43(5):1283-1317.
[10] 张 坦, 李新和, 骆亚洲,等. 工艺参数对薄壁筒变薄旋压的表面残余应力的影响[J]. 锻压技术, 2017, 42(1):47-53.ZHANG Tan,LI XinHe,LUO YaZhou et al. Influence of process parameters on surface residual stress for thin-wall cylindrical part in the reduction spinning[J]. Forming & Stamping Technology, 2017, 42(1):47-53 (In Chinese).
[11] 夏琴香, 周立奎, 肖刚锋,等. 工艺参数对高强钢锥形件剪切旋压成形质量的影响[J]. 锻压技术, 2017, 42(2):77-81.XIA QinXiang,ZHOU LiKui,XIAO GangFeng et al. Influence of process parameters on shear spinning quality for high strength steel conical parts[J]. Forming & Stamping Technology, 2017, 42(2):77-81(In Chinese).
[12] 曹 振, 王旭东, 董 杰,等. AZ80镁合金轮毂强力旋压工艺及组织性能研究[J]. 稀有金属, 2018,42(2):139-145.CAO Zhen,WANG XuDong,DONG Jie et al. Microstructure and mechanical properties of magnesium alloy AZ80 wheelfabricated by power spinning[J]. Chinese Journal of Rare Metals, 2018,42(2):139-145(In Chinese).
[13] 石 珣, 李 言, 杨明顺,等. 金属波纹管内旋压增量成形过程材料变形特性研究[J]. 锻压技术, 2018,43(2):55-61.SHI Xun,LI Yan,YANG MingShun et al. Investigation on deformation characteristics of internal spinning incrementalforming process for metal corrugated tubes[J]. Forming & Stamping Technology, 2018,43(2):55-61(In Chinese).
[14] 柏 朗, 李 言, 杨明顺,等. 超声振动单点增量成形力研究[J]. 机械科学与技术,2018,37(2):270-275.BAI Lang, LI Yan, YANG MingShun et al. Research on forming force in single point incremental forming with ultrasonic vibration[J]. Mechanical Science and Technology for Aerospace Engineering, 2018,37(2):270-275(In Chinese).
[15] 姚梓萌, 李 言, 杨明顺,等. 金属板材单点增量成形过程成形力的研究[J]. 机械科学与技术, 2015,34(7):1044-1047.YAO ZiMeng, LI Yan, YANG MingShun, et al. Study on forming force in single point incremental forming process of sheet metal[J]. Mechanical Science and Technology for Aerospace Engineering, 2015,34(7):1044-1047(In Chinese).
[16] 张 勇, 李鹏阳, 王权岱, 等. 基于ABAQUS的单点增量成形的数值分析[J]. 机械强度, 2015,37(1):99-103.ZHANG Yong, LI PengYang, WANG QuanDai, et al. Based on ABAQUS single point incremental forming numerical analysis[J]. Journal of Mechanical Strength, 2015,37(1):99-103(In Chinese).
[17] 李韩博, 杨明顺, 李 言,等. 灰色关联分析在SPIF表面粗糙度优化中的应用[J]. 机械科学与技术,2017,36(10):1575-1581.LI HanBo, YANG MingShun, LI Yan, et al. Optimization of SPIF surface roughness via grey relational analysis[J]. Mechanical Science and Technology for Aerospace Engineering, 2017,36(10):1575-1581(In Chinese).
[18] 范 渊, 李 言, 杨明顺, 等.金属板料单点增量成形的径向精度研究[J].机械强度.2017,39(2):373-379.FAN Yuan, LI Yan, YANG MingShun, et al. Research on radial accuracy in metal sheet single point incremental forming process[J]. Journal of Mechanical Strength, 2017,39(2):373-379(In Chinese).
[19] 姚梓萌, 李 言,杨明顺, 等.响应面法在单点增量成形质量控制多目标优化中的应用[J]. 机械科学与技术,2017,36(3):409-416.YAO ZiMeng, LI Yan, YANG MingShun, et al. Multi-objective optimization of forming quality in single point incremental forming via response surface methodology[J].Mechanical Science and Technology for Aerospace Engineering, 2017,36(3):409-416(In Chinese).
[20] 柏 朗, 李 言, 杨明顺, 等.工业纯铝1060板料单点增量成形极限实验研究[J]. 机械科学与技术, 2017,36(2):314-318.BAI Lang, LI Yan, YANG MingShun, et al. Experimental investigation of forming limit in single point incremental forming of 1060 aluminum sheet[J]. Mechanical Science and Technology for Aerospace Engineering, 2017,36(3):409-416(In Chinese).
[21] 张敬冲, 李 言, 杨明顺, 等.圆锥台单点增量成形件残余应力研究[J]. 机械科学与技术, 2017,36(10):1626-1632.ZHANG JingChong, LI Yan, YANG MingShun, et al. Study on residual stress of cone part manufactured by single point incremental forming[J]. Mechanical Science and Technology for Aerospace Engineering, 2017,36(10):1626-1632(In Chinese).
[22] 姚梓萌, 李 言, 杨明顺, 等.锥形件单点增量成形过程应变状态研究[J].机械科学与技术, 2016,35(12):1871-1876.YAO ZiMeng, LI Yan, YANG MingShun, et al. Research on deformation states of cone parts via single point incremental forming[J]. Mechanical Science and Technology for Aerospace Engineering, 2016,35(12):1871-1876(In Chinese).
[2] 全国管路附件标准化技术委员会.GB/T14525-2010.波纹管金属软管通用技术条件[S]北京:中国标准出版社,2010:1-8.National Technical Committee for standardization of pipeline accessories. GB/T14525-2010. General technical conditions for corrugated pipe metal hose [S] Beijing: China Standard Press, 2010:1-8(In Chinese).
[3] 王焕庆. 压力容器与换热器膨胀节选用指南.第3册.Vol.3,HTZ-3型膨胀节整体成形加强U形系列基本参数与尺寸,HTZ-3 type[M]. 合肥:合肥工业大学出版社, 2012:78-84.WANG HuanQing. Selection Guide for pressure vessel and heat exchanger expansion joint. Third.Vol.3, HTZ-3 expansion joint integral forming to strengthen the U shape series basic parameters and dimensions, HTZ-3 type[M]. HeFei:HeFei University of Technology Press, 2012:78-84(In Chinese).
[4] Alves L M, Martins P A F. Forming of thin-walled tubes into toroidal shells[J]. Journal of Materials Processing Tech, 2010, 210(4):689-695.
[5] Alves M L, Almeida B P P, Rosa P A R, et al. End forming of thin-walled tubes[J]. Journal of Materials Processing Technology, 2006, 177(1-3):183-187.
[6] Almeida B P P, Alves M L, Rosa P A R, et al. Expansion and reduction of thin-walled tubes using a die: Experimental and theoretical investigation[J]. International Journal of Machine Tools & Manufacture, 2006, 46(12):1643-1652.
[7] Park T D, Kyriakides S. On the collapse of dented cylinders under external pressure[J]. International Journal of Mechanical Sciences, 2015, 38(5):557-578.
[8] Niknejad A, Moeinifard M. Theoretical and experimental studies of the external inversion process in the circular metal tubes[J]. Materials & Design, 2012, 40(9):324-330.
[9] Miller J E, Kyriakides S, Bastard A H. On bend-stretch forming of aluminum extruded tubes - I: Experiments[J]. International Journal of Mechanical Sciences, 2015, 43(5):1283-1317.
[10] 张 坦, 李新和, 骆亚洲,等. 工艺参数对薄壁筒变薄旋压的表面残余应力的影响[J]. 锻压技术, 2017, 42(1):47-53.ZHANG Tan,LI XinHe,LUO YaZhou et al. Influence of process parameters on surface residual stress for thin-wall cylindrical part in the reduction spinning[J]. Forming & Stamping Technology, 2017, 42(1):47-53 (In Chinese).
[11] 夏琴香, 周立奎, 肖刚锋,等. 工艺参数对高强钢锥形件剪切旋压成形质量的影响[J]. 锻压技术, 2017, 42(2):77-81.XIA QinXiang,ZHOU LiKui,XIAO GangFeng et al. Influence of process parameters on shear spinning quality for high strength steel conical parts[J]. Forming & Stamping Technology, 2017, 42(2):77-81(In Chinese).
[12] 曹 振, 王旭东, 董 杰,等. AZ80镁合金轮毂强力旋压工艺及组织性能研究[J]. 稀有金属, 2018,42(2):139-145.CAO Zhen,WANG XuDong,DONG Jie et al. Microstructure and mechanical properties of magnesium alloy AZ80 wheelfabricated by power spinning[J]. Chinese Journal of Rare Metals, 2018,42(2):139-145(In Chinese).
[13] 石 珣, 李 言, 杨明顺,等. 金属波纹管内旋压增量成形过程材料变形特性研究[J]. 锻压技术, 2018,43(2):55-61.SHI Xun,LI Yan,YANG MingShun et al. Investigation on deformation characteristics of internal spinning incrementalforming process for metal corrugated tubes[J]. Forming & Stamping Technology, 2018,43(2):55-61(In Chinese).
[14] 柏 朗, 李 言, 杨明顺,等. 超声振动单点增量成形力研究[J]. 机械科学与技术,2018,37(2):270-275.BAI Lang, LI Yan, YANG MingShun et al. Research on forming force in single point incremental forming with ultrasonic vibration[J]. Mechanical Science and Technology for Aerospace Engineering, 2018,37(2):270-275(In Chinese).
[15] 姚梓萌, 李 言, 杨明顺,等. 金属板材单点增量成形过程成形力的研究[J]. 机械科学与技术, 2015,34(7):1044-1047.YAO ZiMeng, LI Yan, YANG MingShun, et al. Study on forming force in single point incremental forming process of sheet metal[J]. Mechanical Science and Technology for Aerospace Engineering, 2015,34(7):1044-1047(In Chinese).
[16] 张 勇, 李鹏阳, 王权岱, 等. 基于ABAQUS的单点增量成形的数值分析[J]. 机械强度, 2015,37(1):99-103.ZHANG Yong, LI PengYang, WANG QuanDai, et al. Based on ABAQUS single point incremental forming numerical analysis[J]. Journal of Mechanical Strength, 2015,37(1):99-103(In Chinese).
[17] 李韩博, 杨明顺, 李 言,等. 灰色关联分析在SPIF表面粗糙度优化中的应用[J]. 机械科学与技术,2017,36(10):1575-1581.LI HanBo, YANG MingShun, LI Yan, et al. Optimization of SPIF surface roughness via grey relational analysis[J]. Mechanical Science and Technology for Aerospace Engineering, 2017,36(10):1575-1581(In Chinese).
[18] 范 渊, 李 言, 杨明顺, 等.金属板料单点增量成形的径向精度研究[J].机械强度.2017,39(2):373-379.FAN Yuan, LI Yan, YANG MingShun, et al. Research on radial accuracy in metal sheet single point incremental forming process[J]. Journal of Mechanical Strength, 2017,39(2):373-379(In Chinese).
[19] 姚梓萌, 李 言,杨明顺, 等.响应面法在单点增量成形质量控制多目标优化中的应用[J]. 机械科学与技术,2017,36(3):409-416.YAO ZiMeng, LI Yan, YANG MingShun, et al. Multi-objective optimization of forming quality in single point incremental forming via response surface methodology[J].Mechanical Science and Technology for Aerospace Engineering, 2017,36(3):409-416(In Chinese).
[20] 柏 朗, 李 言, 杨明顺, 等.工业纯铝1060板料单点增量成形极限实验研究[J]. 机械科学与技术, 2017,36(2):314-318.BAI Lang, LI Yan, YANG MingShun, et al. Experimental investigation of forming limit in single point incremental forming of 1060 aluminum sheet[J]. Mechanical Science and Technology for Aerospace Engineering, 2017,36(3):409-416(In Chinese).
[21] 张敬冲, 李 言, 杨明顺, 等.圆锥台单点增量成形件残余应力研究[J]. 机械科学与技术, 2017,36(10):1626-1632.ZHANG JingChong, LI Yan, YANG MingShun, et al. Study on residual stress of cone part manufactured by single point incremental forming[J]. Mechanical Science and Technology for Aerospace Engineering, 2017,36(10):1626-1632(In Chinese).
[22] 姚梓萌, 李 言, 杨明顺, 等.锥形件单点增量成形过程应变状态研究[J].机械科学与技术, 2016,35(12):1871-1876.YAO ZiMeng, LI Yan, YANG MingShun, et al. Research on deformation states of cone parts via single point incremental forming[J]. Mechanical Science and Technology for Aerospace Engineering, 2016,35(12):1871-1876(In Chinese).