GH4169叶片冷辊轧成形过程数值模拟分析
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摘要
以航空发动机用GH4169五级叶片冷辊轧工艺为研究对象,应用DEFORM二次开发子程序,向有限元软件中添加适合分析高温合金塑性变形的CHABOCHE本构模型,然后根据实际工况进行辊轧过程数值模拟,所得最大辊轧力和延伸量与实际经验值符合,验证了仿真模型准确性。进一步分析了叶片辊轧过程中材料流动,并探讨了摩擦系数与轧辊转速对叶片辊轧力的影响。结果表明:开始阶段辊轧力较平稳,当轧至叶身2/3附近,由于后滑原因,辊轧力迅速增加约40%;摩擦系数对辊轧力、辊轧力矩有较大的影响,摩擦系数为0.12和0.4时,两者最大辊轧力相差20.2%,而轧辊转速对辊轧力影响较小。
Five grade cold roll-forming process of GH4169 blade was studied in it. Firstly,the CHABOCHE constitutive model for superalloy was added to the DEFORM software by the secondary development,then the numerical simulation of roll process according to the working condition was carried out. Through calculation,the maximum rolling force and blade elongation were in accordance with the practical experience,so it verified the accuracy of the simulation model. Based on the analysis of material flow,the influenceson rolling force of friction coefficient and roll speed were discussed. The results show that the rolling force is stable in the beginning stage,when near 2/3 blade,it increased by about 40% because of backward slip;The friction coefficient has a bigger effect on therolling force,when the friction coefficient is 0.12 and 0.4,The difference between the maximum rolling force is 20.2%,and roll speed has little influence on the rolling force.
Five grade cold roll-forming process of GH4169 blade was studied in it. Firstly,the CHABOCHE constitutive model for superalloy was added to the DEFORM software by the secondary development,then the numerical simulation of roll process according to the working condition was carried out. Through calculation,the maximum rolling force and blade elongation were in accordance with the practical experience,so it verified the accuracy of the simulation model. Based on the analysis of material flow,the influenceson rolling force of friction coefficient and roll speed were discussed. The results show that the rolling force is stable in the beginning stage,when near 2/3 blade,it increased by about 40% because of backward slip;The friction coefficient has a bigger effect on therolling force,when the friction coefficient is 0.12 and 0.4,The difference between the maximum rolling force is 20.2%,and roll speed has little influence on the rolling force.
引文
[1]赵升吨,赵承伟,邵中魁.现代叶片成形工艺的探讨[J].机床与液压,2012,40(21):167-170.(Zhao Sheng-dun,Zhao Cheng-wei,Shao Zhong-kui.Discussion about the modern forming process of blade[J].Machine Tool&Hydraulics,2012,40(21):167-170)
[2]马辉,能海强,吕颂.变厚度壳单元的旋转叶片振动响应分析[J].机械设计与制造,2013(11):109-112.(Ma Hui,Nai Hai-qiang,Lv Song.Vibration response analysis of a rotating blade of variable thickness shell element[J].Machinery Design&Manufacture,2013(11):109-112.)
[3]J.L.Chaboche.Constitutive equations for cyclic plasticity and cyclic viscoplasticity[J].International Journal of Plasticity,1989(5):247-302.
[4]魏洪亮,杨晓光,于慧臣.GH4169高温合金力学行为本构建模及参数识别[J].材料工程,2005(4):42-45.(Wei Hong-liang,Yang Xiao-guang,Yu hui-chen.Constitutive modeling and parameter identification of mechanical behavior for GH4169 alloy at high temperature[J].Materials engineering,2005(4):42-45.)
[5]杨晓光,石多奇.粘塑性本构理论及其应用[M].北京:国防工业出版社,2013.(Yang Xiao-guang,Shi Duo-qi.Visco Plastic Constitutive Theory and Application[M].Beijing:National Defence Industry Press,2013.)
[6]J.L.Chaboche,G.Cailletaud.Integration methods for complex plastic constitutive equations[J].Computer Methods in Applied Mechanics and Engineering,1996(133):125-155.
[7]J.L.Chaboche.A review of some plasticity and viscoplasticity constitutive theories[J].International Journal of Plasticity,2008(24):1642-1693.
[8]B.Lu,H.Ou,C.G.Armstrong.3D Die shape optimization for net-shape forging of aerofoil blades[J].Material and Design,2009(30):2490-2500.
[9]Ding Hanlin,Hirai Kazuki,Homma Tomoyuki,Kamado Shigeharu.Numerical simulation for microstructure evolution in AM50 Mg alloy during hot rolling[J].Computational Materials Science,2010,47(4):919-925.
[10]A.R.Shahani,S.Setayeshi,S.A.Nodamaie.Prediction of influence parameters on the hot rolling process usi ng finite element method and neural network[J].Journal of Material Processing Technology,2009,209(4):1920-1935.
[2]马辉,能海强,吕颂.变厚度壳单元的旋转叶片振动响应分析[J].机械设计与制造,2013(11):109-112.(Ma Hui,Nai Hai-qiang,Lv Song.Vibration response analysis of a rotating blade of variable thickness shell element[J].Machinery Design&Manufacture,2013(11):109-112.)
[3]J.L.Chaboche.Constitutive equations for cyclic plasticity and cyclic viscoplasticity[J].International Journal of Plasticity,1989(5):247-302.
[4]魏洪亮,杨晓光,于慧臣.GH4169高温合金力学行为本构建模及参数识别[J].材料工程,2005(4):42-45.(Wei Hong-liang,Yang Xiao-guang,Yu hui-chen.Constitutive modeling and parameter identification of mechanical behavior for GH4169 alloy at high temperature[J].Materials engineering,2005(4):42-45.)
[5]杨晓光,石多奇.粘塑性本构理论及其应用[M].北京:国防工业出版社,2013.(Yang Xiao-guang,Shi Duo-qi.Visco Plastic Constitutive Theory and Application[M].Beijing:National Defence Industry Press,2013.)
[6]J.L.Chaboche,G.Cailletaud.Integration methods for complex plastic constitutive equations[J].Computer Methods in Applied Mechanics and Engineering,1996(133):125-155.
[7]J.L.Chaboche.A review of some plasticity and viscoplasticity constitutive theories[J].International Journal of Plasticity,2008(24):1642-1693.
[8]B.Lu,H.Ou,C.G.Armstrong.3D Die shape optimization for net-shape forging of aerofoil blades[J].Material and Design,2009(30):2490-2500.
[9]Ding Hanlin,Hirai Kazuki,Homma Tomoyuki,Kamado Shigeharu.Numerical simulation for microstructure evolution in AM50 Mg alloy during hot rolling[J].Computational Materials Science,2010,47(4):919-925.
[10]A.R.Shahani,S.Setayeshi,S.A.Nodamaie.Prediction of influence parameters on the hot rolling process usi ng finite element method and neural network[J].Journal of Material Processing Technology,2009,209(4):1920-1935.