增量成形内凸螺旋波纹管研究
|
摘要
目的研究增量成形螺旋波纹管过程中,工具头的单次压下量与摩擦因数对成形质量和极限的影响规律,优化成形工艺参数。方法通过ABAQUS有限元模拟和实验相结合,对各个成形工艺参数进行有限元模拟;使用前端直径为8 mm的成形工具头对外径40 mm、壁厚0.8 mm的304不锈钢进行增量成形螺旋波纹管实验研究。结果不同摩擦因数对成形极限影响较小,对成形质量有较大影响。单次进给量为0.1 mm,摩擦因数为0.02时,螺纹深度极限可以提高10.5%。模拟和实验都验证了工艺参数的合理性。结论摩擦因数一定的情况下,单次压下量越小,成形力越小,螺纹深度极限越大。
The paper aims to study influences of single reduction and friction coefficient of tool head on forming quality and limit during incremental forming of spiral corrugated tube, and to optimize parameters of forming process. Through combination of ABAQUS finite element simulation and experiments, finite element simulation of each forming process parameter was performed. The spiral corrugated tube was incrementally formed on 304 stainless steel tube with an outer diameter of 40 mm and a wall thickness of 0.8 mm through a forming tool head with a diameter of 8 mm. Different friction coefficients had few influences on forming limit and had large influences on forming quality. When the single feed rate was 0.1 mm, the thread depth limit could be increased by 10.5% when the friction coefficient was 0.02. Both simulations and experiments verified the rationality of process parameters. When the friction coefficient is constant, the smaller the single feed, the smaller the forming force and the greater the thread depth limit.
The paper aims to study influences of single reduction and friction coefficient of tool head on forming quality and limit during incremental forming of spiral corrugated tube, and to optimize parameters of forming process. Through combination of ABAQUS finite element simulation and experiments, finite element simulation of each forming process parameter was performed. The spiral corrugated tube was incrementally formed on 304 stainless steel tube with an outer diameter of 40 mm and a wall thickness of 0.8 mm through a forming tool head with a diameter of 8 mm. Different friction coefficients had few influences on forming limit and had large influences on forming quality. When the single feed rate was 0.1 mm, the thread depth limit could be increased by 10.5% when the friction coefficient was 0.02. Both simulations and experiments verified the rationality of process parameters. When the friction coefficient is constant, the smaller the single feed, the smaller the forming force and the greater the thread depth limit.
引文
[1]GRZANCIC G,HIEGEMANN L,KHALIFA N B.Investigation of New Tool Design for Incremental Profile Forming[J].Procedia Engineering,2017,207:1767—1772.
[2]BECKER C,STAUPENDAHL D,HERMES M,et al.Incremental Tube Forming and Torque Superposed Spatial Bending-a View on Process Parameters[J].Special Edition,2012:415—418.
[3]KIM Y H,PARK J J.Effect of Process Parameters on Formability in Incremental Forming of Sheet Metal[J].Journal of Materials Processing Technology,2002,S130/131(4):42—46.
[4]肖冰,曹红锦,张志明,等.国外金属板材单点渐进成形技术研究的新进[J].精密成形工程,2010,2(5):38—40.XIAO Bing,CAO Hong-jin,ZHANG Zhi-ming,et al.New Development of Foreign Single-point Incremental Metal Sheet Forming[J].Journal of Netshape Forming Engineering,2010,2(5):38—40.
[5]李剑,廖丹佩,詹艳然.螺形波纹管旋压成形过程的尺寸变化特点[J].精密成形工程,2016,8(2):55—58.LI Jian,LIAO Dan-pei,ZHAN Yan-ran.Characteristics of the Dimensional Change during the Spinning Process of Spiral Bellows[J].Journal of Netshape Forming Engineering,2016,8(2):55—58.
[6]吴志伟,钱才富,王薪.螺旋波纹管及其换热器的发展综述[J].化工机械,2018(1):1—5.WU Zhi-wei,QIAN Cai-fu,WANG Xin.Overview of Development of the Spiral Corrugated[J].Tubes and Their Application in Heat Exchangers,2018(1):1—5.
[7]钱泰磊.新型螺旋三叶管油冷却器的传热及压降性能研究[D].上海:华东理工大学,2014.QIAN Tai-lei.Study on Heat Transfer and Pressure Drop Performance of a New Type Helical Clover Oil Cooler[D].Shanghai:East China University of Science and Technology,2014.
[8]GRZANCIC G,BECKER C,HERMES M,et al.Innovative Machine Design for Incremental Profile Forming[J].Key Engineering Materials,2014,622/623:413—419.
[9]BECKER C,TEKKAYA A E,KLEINER M.Fundamentals of the Incremental Tube Forming Process[J].CIRP Annals-Manufacturing Technology,2014,63(1):253—256.
[10]WEN T,YANG C,ZHANG S,et al.Characterization of Deformation Behavior of Thin-walled Tubes during Incremental Forming:a Study with Selected Examples[J].International Journal of Advanced Manufacturing Technology,2015,78(9/10/11/12):1769—1780.
[11]钟建华,张建新,张峰,等.内螺旋外波纹铜管成形工艺研究[J].精密成形工程,2001,19(6):14—16.ZHONG Jian-hua,ZHANG Jian-xin,ZHANG Feng,et al.A Study on the Forming Technology of Copper Tube with Internal-helical External-ripple[J].Journal of Netshape Forming Engineering,2001,19(6):14—16.
[12]张士宏,袁安营.板材与管材成形性能的研究与进展[J].精密成形工程,2009,1(1):1—6.ZHANG Shi-hong,YUAN An-ying.Research and Development of Formability of Plates and Tubes[J].Journal of Netshape Forming Engineering,2009,1(1):1—6.
[13]詹梅,石丰,邓强,等.铝合金波纹管无芯模缩径旋压成形机理与规律[J].塑性工程学报,2014,21(2):108—115.ZHAN Mei,SHI Feng,DENG Qiang,et al.Forming Mechanism and Rules of Mandreless Neck-spinning on Corrugated Pipes[J].Journal of Plasticity Engineering,2014,21(2):108—115.
[14]李超玲.筒形件强力旋压过程的有限元数值模拟[D].西安:西北工业大学,2004.LI Chao-ling.Finite Element Numerical Simulation of Spinning Process of Cylindrical Pieces[D].Xi'an:Northwestern Polytechnical University,2004.
[15]GRZANCIC G,BECKER C,KHALIFA N B.Basic Analysis of the Incremental Profile Forming Process[J].Journal of Manufacturing Science&Engineering,2016,138(9):2—6.
[2]BECKER C,STAUPENDAHL D,HERMES M,et al.Incremental Tube Forming and Torque Superposed Spatial Bending-a View on Process Parameters[J].Special Edition,2012:415—418.
[3]KIM Y H,PARK J J.Effect of Process Parameters on Formability in Incremental Forming of Sheet Metal[J].Journal of Materials Processing Technology,2002,S130/131(4):42—46.
[4]肖冰,曹红锦,张志明,等.国外金属板材单点渐进成形技术研究的新进[J].精密成形工程,2010,2(5):38—40.XIAO Bing,CAO Hong-jin,ZHANG Zhi-ming,et al.New Development of Foreign Single-point Incremental Metal Sheet Forming[J].Journal of Netshape Forming Engineering,2010,2(5):38—40.
[5]李剑,廖丹佩,詹艳然.螺形波纹管旋压成形过程的尺寸变化特点[J].精密成形工程,2016,8(2):55—58.LI Jian,LIAO Dan-pei,ZHAN Yan-ran.Characteristics of the Dimensional Change during the Spinning Process of Spiral Bellows[J].Journal of Netshape Forming Engineering,2016,8(2):55—58.
[6]吴志伟,钱才富,王薪.螺旋波纹管及其换热器的发展综述[J].化工机械,2018(1):1—5.WU Zhi-wei,QIAN Cai-fu,WANG Xin.Overview of Development of the Spiral Corrugated[J].Tubes and Their Application in Heat Exchangers,2018(1):1—5.
[7]钱泰磊.新型螺旋三叶管油冷却器的传热及压降性能研究[D].上海:华东理工大学,2014.QIAN Tai-lei.Study on Heat Transfer and Pressure Drop Performance of a New Type Helical Clover Oil Cooler[D].Shanghai:East China University of Science and Technology,2014.
[8]GRZANCIC G,BECKER C,HERMES M,et al.Innovative Machine Design for Incremental Profile Forming[J].Key Engineering Materials,2014,622/623:413—419.
[9]BECKER C,TEKKAYA A E,KLEINER M.Fundamentals of the Incremental Tube Forming Process[J].CIRP Annals-Manufacturing Technology,2014,63(1):253—256.
[10]WEN T,YANG C,ZHANG S,et al.Characterization of Deformation Behavior of Thin-walled Tubes during Incremental Forming:a Study with Selected Examples[J].International Journal of Advanced Manufacturing Technology,2015,78(9/10/11/12):1769—1780.
[11]钟建华,张建新,张峰,等.内螺旋外波纹铜管成形工艺研究[J].精密成形工程,2001,19(6):14—16.ZHONG Jian-hua,ZHANG Jian-xin,ZHANG Feng,et al.A Study on the Forming Technology of Copper Tube with Internal-helical External-ripple[J].Journal of Netshape Forming Engineering,2001,19(6):14—16.
[12]张士宏,袁安营.板材与管材成形性能的研究与进展[J].精密成形工程,2009,1(1):1—6.ZHANG Shi-hong,YUAN An-ying.Research and Development of Formability of Plates and Tubes[J].Journal of Netshape Forming Engineering,2009,1(1):1—6.
[13]詹梅,石丰,邓强,等.铝合金波纹管无芯模缩径旋压成形机理与规律[J].塑性工程学报,2014,21(2):108—115.ZHAN Mei,SHI Feng,DENG Qiang,et al.Forming Mechanism and Rules of Mandreless Neck-spinning on Corrugated Pipes[J].Journal of Plasticity Engineering,2014,21(2):108—115.
[14]李超玲.筒形件强力旋压过程的有限元数值模拟[D].西安:西北工业大学,2004.LI Chao-ling.Finite Element Numerical Simulation of Spinning Process of Cylindrical Pieces[D].Xi'an:Northwestern Polytechnical University,2004.
[15]GRZANCIC G,BECKER C,KHALIFA N B.Basic Analysis of the Incremental Profile Forming Process[J].Journal of Manufacturing Science&Engineering,2016,138(9):2—6.