铲旋工艺的有限元分析及试验研究
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摘要
针对含法兰盘双筒形零件内筒成形的铲旋工艺,设计了一种半封闭式双铲旋轮结构,基于Simufact软件平台建立三维铲旋刚塑性有限元模型,对铲旋工艺的成形效果进行分析,并采用CDC-60型旋压机床进行试模验证试验.结果表明,在铲旋成形过程中,变形区的金属始终处于受力不均、受挤压的状态,从而发生轴向、径向、切向的位移,并产生轴向长高、径向增厚的效应.在铲旋成形后期,底部金属所受小变形区的阻力作用增强,使其径向增厚受阻,从而在筒壁内侧出现了欠料缺陷,而且进给距离越大,其增厚效应和欠料缺陷越明显.试验所得旋轮内筒的有效高度和壁厚分别为35.0、6.9 mm,超过铲旋厚度的15和3倍,试模试验结果与模拟结果的误差小于10%,从而验证了数值模型的可靠性和半封闭式铲旋轮结构的可行性.
By introducing a double-spinning rollers and its semi-enclosed structure of shovel spinning, a 3D rigid-plastic finite element method model of the spinning process of the inner cylinder on double cylindrical parts with flange was established on the platform of Simufact, and was used to validate the forming effect. The material in the major deformation zone has the displacement toward the axial, radial and tangential directions due to the compressive stress with nonuniform distribution during shovel spinning processing, therefore the inner cylinder exhibits an increasing effect in the axial length and the radial thickness. At the later stage of forming, the metal at the bottom is easier to be subjected to the compressive stress from the metal in the small deformation zone, which results in the difficulty of radial thickness and the lack of material on the inside of the barrel wall appeared. The greater the feed distance is, the more obvious the thickening effect and the lack of material are. The spinning process was tested on the spinning machine of CDC-60, and the results show that the effective height and the effective thickness can reach to 35.0 mm and 6.9 mm, respectively, which are over 15 times and 3 times of the thickness of shovel spinning, the errors of simulated and test results were less than 10%. The feasibility of numerical simulation analysis and semi-closed spinning roller structure is verified.
By introducing a double-spinning rollers and its semi-enclosed structure of shovel spinning, a 3D rigid-plastic finite element method model of the spinning process of the inner cylinder on double cylindrical parts with flange was established on the platform of Simufact, and was used to validate the forming effect. The material in the major deformation zone has the displacement toward the axial, radial and tangential directions due to the compressive stress with nonuniform distribution during shovel spinning processing, therefore the inner cylinder exhibits an increasing effect in the axial length and the radial thickness. At the later stage of forming, the metal at the bottom is easier to be subjected to the compressive stress from the metal in the small deformation zone, which results in the difficulty of radial thickness and the lack of material on the inside of the barrel wall appeared. The greater the feed distance is, the more obvious the thickening effect and the lack of material are. The spinning process was tested on the spinning machine of CDC-60, and the results show that the effective height and the effective thickness can reach to 35.0 mm and 6.9 mm, respectively, which are over 15 times and 3 times of the thickness of shovel spinning, the errors of simulated and test results were less than 10%. The feasibility of numerical simulation analysis and semi-closed spinning roller structure is verified.
引文
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[2] XIA Q X,XIAO G F,LONG H,et al.A review of process advancement of novel metal spinning[J].International Journal of Machine Tools and Manufacture,2014,85:100-121.
[3] 王成和,刘克璋,周路.旋压技术[M].福州:福建科学技术出版社,2017.WANG Chenghe,LIU Kezhang,ZHOU Lu.Spinning technology [M].Fuzhou:Fujian Science and Technology Press,2017.
[4] 梁卫抗,刘全坤,张宜生,等.发动机减震器带轮内筒的铲旋成形模拟及试验[J].塑性工程学报,2011,18(3):66-69.LIANG Weikang,LIU Quankun,ZHANG Yisheng,et al.Simulation and experiment on the forming of inner cylinder of engine absorber pulley by shovel spinning technology[J].Journal of Plasticity Engineering,2011,18 (3):66-69.
[5] 沈国章.皮带轮轮毂旋压成形中变形稳定性研究[D].合肥:合肥工业大学,2014.SHEN Guozhang.Study on the stability of forming mechanism in boss forming of cylinder of belt pulley[D].Hefei:Hefei University of Technology,2014.
[6] 赵云豪,李彦利.旋压技术与应用[M].北京:机械工业出版社,2007.ZHAO Yunhao,LI Yanli.The technology and application of spinning[M].Beijing:China Machine Press,2007.
[7] 路平,张云开,陈波.汽车轮辐错距强力旋压成形的有限元仿真[J].上海交通大学学报,2015,49(1):56-61.LU Ping,ZHANG Yunkai,CHEN Bo.Finite element method simulation of stagger power spinning forming of automobile spoke[J].Journal of Shanghai Jiao Tong University,2015,49(1):56-61.
[8] 詹梅,郭靖,陈飞,等.带横向内筋特征构件外强旋压成形机理研究[J].西北工业大学学报,2014,32(5):799-804.ZHAN Mei,GUO Jing,CHEN Fei,et al.Exploring forming mechanism of a part with transverse inner rib during power spinning[J].Journal of Northwestern Polytechnical University,2014,32(5):799-804.
[9] XIAO G F,XIA Q X,CHENG X Q,et al.Metal flow model of cylindrical parts by counter-roller spinning[J].Procedia Engineering,2014,81:2397-2402.
[10] ROY M J,KLASSEN R J,WOOD J T.Evolution of plastic strain during a flow forming process[J].Journal of Materials Processing Technology,2009,209(2):1018-1025.