钛合金弯管动态流量控制法挤压成形的模拟与实验研究
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摘要
通过有限元分析和实验研究动态流量控制法挤压钛合金弯管件。实验验证弯管的尺寸精度和挤压载荷。分析调控量对弯曲曲率的影响、速度场和温度场。结果表明:挤压载荷的峰值误差为14.51%,挤出的管材弯曲曲率误差为3.47%;在模具结构中,调控通道Ⅱ截面面积不变时,弯管曲率半径随调控通道Ⅰ有效截面面积的增大而增大;在定径带处的合金呈非均匀流动,弯管件内外弧面存在流速差是挤出弯曲件的原因;合金的流速在通过定径带时发生分流补偿,由调控通道Ⅱ进入定径带的合金流速反超辅助通道内的流速,在焊合腔内边缘处存在金属流动死区。在定径带区域温升明显,最大温升为134℃。
The dynamic flow control extrusion(DFCE) of titanium alloy bending tubes was examined in the present study using both the finite element analysis and the experimental approach. The finite element analysis was first validated qualitatively and quantitatively by the experimental data obtained from the DFCE process. The effects of the area of channel cross section on the radius of curvature were studied by the finite element analysis. The fields of velocity and temperature of workpiece were studied. The results show that the relative errors of extrusion load and radius of curvature are 14.51% and 3.47%, respectively. The finite element analysis reveals that radius of curvature increases with the increase of cross-sectional area of controlling channel-Ⅰ. The different cross-sectional area of controlling channel-Ⅰand Ⅱ is found to be one major reason for the extrusion of bending tube. The velocity of workpiece is inhomogeneous in circumferential of bearing zone. The velocity of alloy flowing through die bearing from controlling channel-Ⅱincreases rapidly than that from auxiliary channel. The temperature rise is obviously and the maximum value is 134℃.
The dynamic flow control extrusion(DFCE) of titanium alloy bending tubes was examined in the present study using both the finite element analysis and the experimental approach. The finite element analysis was first validated qualitatively and quantitatively by the experimental data obtained from the DFCE process. The effects of the area of channel cross section on the radius of curvature were studied by the finite element analysis. The fields of velocity and temperature of workpiece were studied. The results show that the relative errors of extrusion load and radius of curvature are 14.51% and 3.47%, respectively. The finite element analysis reveals that radius of curvature increases with the increase of cross-sectional area of controlling channel-Ⅰ. The different cross-sectional area of controlling channel-Ⅰand Ⅱ is found to be one major reason for the extrusion of bending tube. The velocity of workpiece is inhomogeneous in circumferential of bearing zone. The velocity of alloy flowing through die bearing from controlling channel-Ⅱincreases rapidly than that from auxiliary channel. The temperature rise is obviously and the maximum value is 134℃.
引文
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[17]WU Y P,ZHANG X M,DENG Y L,TANG C P,ZHONG Y Y.Effect of secondary extrusion on the microstructure and mechanical properties of a Mg-RE alloy[J].Materials Science and Engineering A,2014,616:148-154.
[18]TANG D,FANG W L,FAN X H,LI D Y,PENG Y H.Effect of die design in microchannel tube extrusion[J].Procedia Engineering,2014,81:628-633.
[19]TANG D,ZHANG Q Q,LI D Y,PENG Y H.A physical simulation of longitudinal seam welding in micro channel tube extrusion[J].Journal of Materials Processing Technology,2014,214:2777-2783.
[20]石磊,徐国辉,任畅,金文中,王玉江,王利剑.动态流量控制法挤出镁合金三维弯曲管件[J].材料科学与工艺,2016,24(6):9-14.SHI Lei,XU Guo-hui,REN Chang,JIN Wen-zhong,WANGYu-jiang,WANG Li-jiang.Three dimensional magnesium alloy bent pipe produced by dynamic flow control extrusion[J].Materials Science&Technology,2016,24(6):8-13.
[21]WU C,YANG H,LI H W.Simulated and experimental investigation on discontinuous dynamic recrystallization of a near-αTA 15 titanium alloy during isothermal hot compression inβsingle-phase field[J].Transactions of Nonferrous Metals Society of China,2014,24(6):1819-1829.
[2]XUE X,LIAO J,VINCZE G,GRACIO J J.Modelling of mandrel rotary draw bending for accurate twist springback prediction of an asymmetric thin-walled tube[J].Journal of Materials Processing Technology,2015,216:405-417.
[3]刘泽宇,滕步刚,苑世剑.内压对薄壁管充液压弯时的影响[J].塑性工程学报,2009,16(4):35-38.LIU Ze-yu,TENG Bu-gang,YUAN Shi-jian.Effect of internal pressure on thin-walled tubes bending with internal pressure[J].Journal of Plasticity Engineering,2009,16(4):35-38.
[4]YANG H,LI H,ZHANG Z Y,ZHAN M,LIU J,LI G J.Advances and trends on tube bending forming technologies[J].Chinese Journal of Aeronautics,2012,25:1-12.
[5]杨合,孙志超,林艳,李明奇.管成形技术发展基础问题研究[J].塑性工程学报,2001,8:83-85.YANG He,SUN Zhi-chao,LIN Yan,LI Ming-qi.Advanced plastic processing technology and research progress on tube forming[J].Journal of Plasticity Engineering,2001,8:83-85.
[6]张敬文,鄂大辛,李延民,田鑫.弯曲速度对弯管壁厚变化的影响[J].精密成形工程,2012,4(1):5-8.ZHANG Jing-wen,E Da-xin,LI Yan-min,TIAN Xin.Effects of bending velocity on the changer of wall thickness in tube bending[J].Journal of Netshape Forming Engineering,2012,4(1):5-8.
[7]ZHAO G Y,LIU Y L,YANG H,LU C H.Cross-sectional distortion behaviors of thin-walled rectangular tube in rotary-draw bending process[J].Transactions of Nonferrous Metals Society of China,2010,20(3):484-489.
[8]LI H,YANG H,ZHANG Z Y,WANG Z K.‘Size effect’related bending formability of thin-walled aluminum alloy tube[J].Chinese Journal of Aeronautics,2013,26(1):230-241.
[9]TIAN S,LIU Y L,YANG H.Effects of geometrical parameters on wrinkling of thin-walled rectangular aluminum alloy wave-guide tubes in rotary-draw bending[J].Chinese Journal of Aeronautics,2013,26(1):242-248.
[10]LIAO J,XUE X,LEE M G,BARLAT F,GRACIO J.On twist springback prediction of asymmetric tube in rotary draw bending with different constitutive models[J].International Journal of Mechanical Sciences,2014,89:311-322.
[11]LIAO J,XUE X,BARLAT F,GRACIO J.Material modelling and springback analysis for multi-stage rotary draw bending of thin-walled tube using homogeneous anisotropic hardening model[J].Procedia Engineering,2014,81:1228-1233.
[12]TAO Z J,YANG H,LI H,ZHANG Z Y,CHEN Z M.Coupled thermo-mechanical FE simulation of unloading cooling springback in NC heating bending of large diameter thin-walled commercial pure titanium tube[J].Procedia Engineering,2014,81:2273-2279.
[13]ZHU Y X,LIU Y L,YANG H,LI H P.Improvement of the accuracy and the computational efficiency of the springback prediction model for the rotary-draw bending of rectangular H96tube[J].International Journal of Mechanical Sciences,2013,66:224-232.
[14]E D X,LIU Y F.Springback and time-dependent springback of1Cr18Ni9Ti stainless steel tubes under bending[J].Materials and Design,2010,31:1256-1261.
[15]YANG Y L,ZHAN L H,LI J.Constitutive modeling and springback simulation for 2524 aluminum alloy in creep age forming[J].Transactions of Nonferrous Metals Society of China,2015,25(9):3048-3055.
[16]胡渊蔚,吉泽升,徐宇鹏.挤压比对Al-Cu-Mg-Ag-Er合金线材组织及性能影响[J].材料热处理学报,2015,36(2):49-54.HU Yuan-wei,JI Ze-sheng,XU Yu-peng.Effects of extrusion ratio on microstructure and properties of Al-Cu-Mg-Ag-Er alloy wire[J].Transactions of Materials and Heat Treatment,2015,36(2):49-54.
[17]WU Y P,ZHANG X M,DENG Y L,TANG C P,ZHONG Y Y.Effect of secondary extrusion on the microstructure and mechanical properties of a Mg-RE alloy[J].Materials Science and Engineering A,2014,616:148-154.
[18]TANG D,FANG W L,FAN X H,LI D Y,PENG Y H.Effect of die design in microchannel tube extrusion[J].Procedia Engineering,2014,81:628-633.
[19]TANG D,ZHANG Q Q,LI D Y,PENG Y H.A physical simulation of longitudinal seam welding in micro channel tube extrusion[J].Journal of Materials Processing Technology,2014,214:2777-2783.
[20]石磊,徐国辉,任畅,金文中,王玉江,王利剑.动态流量控制法挤出镁合金三维弯曲管件[J].材料科学与工艺,2016,24(6):9-14.SHI Lei,XU Guo-hui,REN Chang,JIN Wen-zhong,WANGYu-jiang,WANG Li-jiang.Three dimensional magnesium alloy bent pipe produced by dynamic flow control extrusion[J].Materials Science&Technology,2016,24(6):8-13.
[21]WU C,YANG H,LI H W.Simulated and experimental investigation on discontinuous dynamic recrystallization of a near-αTA 15 titanium alloy during isothermal hot compression inβsingle-phase field[J].Transactions of Nonferrous Metals Society of China,2014,24(6):1819-1829.