6061铝合金深孔连接锻件模锻成形模拟研究
|
摘要
针对某深孔连接锻件用材料6061铝合金,进行热压缩试验,获得不同应变速率和温度下的流变应力曲线,并通过数据拟合得到该合金流变应力方程;基于DEFORM-3D有限元软件对6061铝合金深孔连接锻件折叠缺陷进行模锻模拟分析。模拟结果表明,锻件成形过程形成弯曲弧面,从而造成金属压缩折叠。通过对原始坯料形状进行改进,即增加预锻,解决了折叠缺陷问题;同时对原始模具结构进行改进,即增加飞边槽,使金属更容易充满模腔;分析优化坯料温度、模具预热温度、摩擦因子等对锻件成形的影响,从而确立较佳的变形参数。试验验证结果表明,锻件成形质量较好,模拟优化较合理。
The rheological stress curves of 6061 aluminum alloy used for deep hole connection forgings under different strain rates and temperatures were obtained by thermal compression test. The rheological stress equation of the alloy was obtained by data fitting. Based on DEFORM-3 D finite element software,the folding defects of 6061 aluminum alloy deep hole connection forgings were simulated and analyzed. The simulation results show that curved arc surface is formed in the forming process,which causes the metal to be compressed and folded. The folding defects of the forging are eliminated by improving the shape of the original blank( adding preforging). The cavity is filled easier by metal through improving the original mold structure( adding flash groove). To obtain optimization deformation parameters,the influence of the blank temperature,the mold preheating temperature and the friction factor on forgings was analyzed. The experimental results show that the forming quality of forgings is good and the simulation optimization is reasonable.
The rheological stress curves of 6061 aluminum alloy used for deep hole connection forgings under different strain rates and temperatures were obtained by thermal compression test. The rheological stress equation of the alloy was obtained by data fitting. Based on DEFORM-3 D finite element software,the folding defects of 6061 aluminum alloy deep hole connection forgings were simulated and analyzed. The simulation results show that curved arc surface is formed in the forming process,which causes the metal to be compressed and folded. The folding defects of the forging are eliminated by improving the shape of the original blank( adding preforging). The cavity is filled easier by metal through improving the original mold structure( adding flash groove). To obtain optimization deformation parameters,the influence of the blank temperature,the mold preheating temperature and the friction factor on forgings was analyzed. The experimental results show that the forming quality of forgings is good and the simulation optimization is reasonable.
引文
[1]于洪兵,杜艳丽.合金化及热处理对汽车用6061铝合金组织与性能的影响[J].铸造技术,2017,38(10):2374-2376.YU Hongbing,DU Yanli. Effect of alloying and heat treatment on microstructure and properties of 6061 aluminum alloy for automobile[J]. Foundry Technology,2017,38(10):2374-2376.
[2]付锦,戚文军,李亚江,等. Al-Mg-Si系合金汽车车身板的研究与进展[J].材料研究与应用,2016,10(3):159-166.FU Jin,QI Wenjun,LI Yajiang,et al. Research and development of Al-Mg-Si alloys in application of auto motive body panel[J]. Materials Research and Application, 2016,10(3):159-166.
[3]程巨强,刘志学.金属锻造加工基础[M].北京:化学工业出版社,2012.
[4]孙钦贺.轴承套圈锻造折叠裂纹缺陷分析[J].金属加工(热加工),2017,(17):18-19.SUN Qinhe. Analysis of forging and folding cracks of bearing ring[J]. Metal Working,2017,(17):18-19.
[5]陈驰,李朝亮,陈文琳.链轨节锻造数值模拟及模具改进[J].模具工业,2018,44(10):69-73.CHEN Chi,LI Zhaoliang,CHEN Wenlin. Numerical simulation of forging track link and the die improvement[J]. Die&Mould Industry,2018,44(10):69-73.
[6]胡晓峰,邱建新,邵超,等. RV减速器输出盘锻造工艺研究及数值模拟分析[J].锻压技术,2018,43(8):8-16.HU Xiaofeng,QIU Jianxin,SHAO Chao,et al. Study on forging technology and numerical simulation analysis for output flange of RV reducer[J]. Forging&Stamping Technology,2018,43(8):8-16.
[7]王玉红,马廷威. DEFORM模拟支撑辊的锻造[J].锻压技术,2017,42(8):185-190.WANG Yuhong,MA Tingwei. Simulation on forging of back-up roll by DEFORM[J]. Forging&Stamping Technology,2017,42(8):185-190.
[8]李凤娇,翟月雯,边翊,等. 6061铝合金高温流变行为[J].塑性工程学报,2015,22(2):95-99.LI Fengjiao,ZHAI Yuewen,BIAN Yi,et al. Study of deformation behavior of 6061 aluminum alloy[J]. Journal of Plasticity Engineering,2015,22(2):95-99.
[9]潘光永. TC16钛合金的高温塑性变形行为研究[J].特种铸造及有色合金,2017,37(8):907-911.PAN Guangyong. Dynamic recrystallization behavior research of TC16 titanium alloy hot deformation process[J]. Special Casting&Nonferrous Alloys,2017,37(8):907-911.
[10]梁培新,翟月雯,刘桂华,等. Ti3Al基合金的热变形行为及本构方程[J].塑性工程学报,2017,24(2):174-178.LIANG Peixin,ZHAI Yuewen,LIU Guihua,et al. Hot deformation behavior and constitutive equation of Ti3Al-based alloy[J].Journal of Plasticity Engineering,2017,24(2):174-178.
[11]王刚,李志广,谢华,等.开闩板成形工艺和锻模设计[J].模具制造,2011,(8):49-51.WANG Gang,LI Zhiguang,XIE Hua, et al. Forming process and forging die design of the open latch plate[J]. Die&Mould Manufacture,2011,(8):49-51.
[12]易幼平,刘超,黄始全.基于DEFORM-3D的7050铝合金动态再结晶元胞自动机模拟[J].中南大学学报:自然科学版,2010,41(5):1814-1820.YI Youping,LIU Chao,HUANG Shiquan. Simulation of dynamic recrystallization for 7050 aluminium alloy on platform of DEFORM-3D using cellular automaton[J]. Journal of Central South University:Science and Technology,2010,41(5):1814-1820.
[13]董洪波,余新平,章威. Q550D超低碳贝氏体钢的微观组织模拟[J].上海交通大学学报,2015,49(1):67-73.DONG Hongbo,YU Xinping,ZHANG wei. Microstructure simulation of Q550D ultra low carbon bainite steel[J]. Journal of Shanghai Jiaotong University,2015,49(1):67-73.
[14]金朝阳,崔振山.变形温度对动态再结晶行为的影响[J].扬州大学学报:自然科学版,2011,14(2):60-64.JIN Zhaoyang,CUI Zhenshan. The effect of deformation temperature on dynamic recrystallization[J]. Journal of Yangzhou University:Natural Science Edition,2011,14(2):60-64.
[15]陈学文,王进,陈军,等.基于最小损伤值的齿轮毛坯锻造成形过程工艺参数优化设计[J].上海交通大学学报,2005,39(7):1070-1072.CHEN Xuewen,WANG Jin,CHEN Jun,et al. The technological parameter optimization of gear billet hot forging process with damage minimization[J]. Journal of Shanghai Jiaotong University,2005,39(7):1070-1072.
[16]赵毅,刘淑梅,何文涛,等.基于正交试验的转向节热模锻工艺参数优化[J].上海工程技术大学学报,2016,30(2):117-121.ZHAO Yi, LIU Shumei, HE Wentao, et al. Optimization of Process parameters in steering knuckle forging based on orthogonal test[J]. Journal of Shanghai University of Engineering Science,2016,30(2):117-121.
[17]张丽霞,李达,张超彦.伞形筒热挤压工艺及模具设计[J].铸造技术,2017,38(11):2730-2733.ZHANG Lixia,LI Da,ZHANG Chaoyan. Hot extrusion process and die design on umbrella-type cylinder[J]. Foundry Technology,2017,38(11):2730-2733.
[2]付锦,戚文军,李亚江,等. Al-Mg-Si系合金汽车车身板的研究与进展[J].材料研究与应用,2016,10(3):159-166.FU Jin,QI Wenjun,LI Yajiang,et al. Research and development of Al-Mg-Si alloys in application of auto motive body panel[J]. Materials Research and Application, 2016,10(3):159-166.
[3]程巨强,刘志学.金属锻造加工基础[M].北京:化学工业出版社,2012.
[4]孙钦贺.轴承套圈锻造折叠裂纹缺陷分析[J].金属加工(热加工),2017,(17):18-19.SUN Qinhe. Analysis of forging and folding cracks of bearing ring[J]. Metal Working,2017,(17):18-19.
[5]陈驰,李朝亮,陈文琳.链轨节锻造数值模拟及模具改进[J].模具工业,2018,44(10):69-73.CHEN Chi,LI Zhaoliang,CHEN Wenlin. Numerical simulation of forging track link and the die improvement[J]. Die&Mould Industry,2018,44(10):69-73.
[6]胡晓峰,邱建新,邵超,等. RV减速器输出盘锻造工艺研究及数值模拟分析[J].锻压技术,2018,43(8):8-16.HU Xiaofeng,QIU Jianxin,SHAO Chao,et al. Study on forging technology and numerical simulation analysis for output flange of RV reducer[J]. Forging&Stamping Technology,2018,43(8):8-16.
[7]王玉红,马廷威. DEFORM模拟支撑辊的锻造[J].锻压技术,2017,42(8):185-190.WANG Yuhong,MA Tingwei. Simulation on forging of back-up roll by DEFORM[J]. Forging&Stamping Technology,2017,42(8):185-190.
[8]李凤娇,翟月雯,边翊,等. 6061铝合金高温流变行为[J].塑性工程学报,2015,22(2):95-99.LI Fengjiao,ZHAI Yuewen,BIAN Yi,et al. Study of deformation behavior of 6061 aluminum alloy[J]. Journal of Plasticity Engineering,2015,22(2):95-99.
[9]潘光永. TC16钛合金的高温塑性变形行为研究[J].特种铸造及有色合金,2017,37(8):907-911.PAN Guangyong. Dynamic recrystallization behavior research of TC16 titanium alloy hot deformation process[J]. Special Casting&Nonferrous Alloys,2017,37(8):907-911.
[10]梁培新,翟月雯,刘桂华,等. Ti3Al基合金的热变形行为及本构方程[J].塑性工程学报,2017,24(2):174-178.LIANG Peixin,ZHAI Yuewen,LIU Guihua,et al. Hot deformation behavior and constitutive equation of Ti3Al-based alloy[J].Journal of Plasticity Engineering,2017,24(2):174-178.
[11]王刚,李志广,谢华,等.开闩板成形工艺和锻模设计[J].模具制造,2011,(8):49-51.WANG Gang,LI Zhiguang,XIE Hua, et al. Forming process and forging die design of the open latch plate[J]. Die&Mould Manufacture,2011,(8):49-51.
[12]易幼平,刘超,黄始全.基于DEFORM-3D的7050铝合金动态再结晶元胞自动机模拟[J].中南大学学报:自然科学版,2010,41(5):1814-1820.YI Youping,LIU Chao,HUANG Shiquan. Simulation of dynamic recrystallization for 7050 aluminium alloy on platform of DEFORM-3D using cellular automaton[J]. Journal of Central South University:Science and Technology,2010,41(5):1814-1820.
[13]董洪波,余新平,章威. Q550D超低碳贝氏体钢的微观组织模拟[J].上海交通大学学报,2015,49(1):67-73.DONG Hongbo,YU Xinping,ZHANG wei. Microstructure simulation of Q550D ultra low carbon bainite steel[J]. Journal of Shanghai Jiaotong University,2015,49(1):67-73.
[14]金朝阳,崔振山.变形温度对动态再结晶行为的影响[J].扬州大学学报:自然科学版,2011,14(2):60-64.JIN Zhaoyang,CUI Zhenshan. The effect of deformation temperature on dynamic recrystallization[J]. Journal of Yangzhou University:Natural Science Edition,2011,14(2):60-64.
[15]陈学文,王进,陈军,等.基于最小损伤值的齿轮毛坯锻造成形过程工艺参数优化设计[J].上海交通大学学报,2005,39(7):1070-1072.CHEN Xuewen,WANG Jin,CHEN Jun,et al. The technological parameter optimization of gear billet hot forging process with damage minimization[J]. Journal of Shanghai Jiaotong University,2005,39(7):1070-1072.
[16]赵毅,刘淑梅,何文涛,等.基于正交试验的转向节热模锻工艺参数优化[J].上海工程技术大学学报,2016,30(2):117-121.ZHAO Yi, LIU Shumei, HE Wentao, et al. Optimization of Process parameters in steering knuckle forging based on orthogonal test[J]. Journal of Shanghai University of Engineering Science,2016,30(2):117-121.
[17]张丽霞,李达,张超彦.伞形筒热挤压工艺及模具设计[J].铸造技术,2017,38(11):2730-2733.ZHANG Lixia,LI Da,ZHANG Chaoyan. Hot extrusion process and die design on umbrella-type cylinder[J]. Foundry Technology,2017,38(11):2730-2733.