带I型纵筋薄壁构件挤压成形数值模拟与工艺优化
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摘要
带I型纵筋薄壁构件的结构复杂、壁厚不均,在挤压过程中容易发生金属流动不均匀现象,导致型材发生翘曲变形。针对该问题,采用Hyper Xtrude有限元分析软件,研究了挤压速度、坯料初始温度和模具初始温度等工艺参数对挤压成形效果的影响规律,发现坯料初始温度的增大会使金属流速更加均匀,而过大的挤压速度和模具初始温度会加大金属流速的不均匀性。通过正交试验获得最佳成形工艺参数组合:挤压速度为2 mm·s~(-1),坯料初始温度为480℃,模具初始温度为440℃。最后进行了相应的挤压试验,并成功获得高精度带I型纵筋薄壁构件样品。该研究工作为此类构件的挤压成形工艺及模具的优化设计提供了理论参考。
The thin-walled component with I-type longitudinal ribs has complex structure and uneven wall thickness,and it is easy to occur uneven metal flow during extrusion process,which leads to warping deformation of profile. For the above problem,the influences of process parameters such as extrusion speed,initial temperature of blank and initial temperature of die on the extrusion forming effect were studied by finite element analysis software Hyper Xtrude. It is found that the increase of initial temperature of blank makes the metal flow velocity more uniform,while the excessive extrusion speed and initial temperature of die increase the non-uniformity of metal flow velocity.Furthermore,the optimum combination of forming process parameters was obtained with the extrusion speed of 2 mm·s~(-1),the initial temperature of blank of 480 ℃ and the initial temperature of die of 440 ℃ by orthogonal test. Finally,the corresponding extrusion tests were carried out,and the high-precision samples of thin-walled component with I-type longitudinal ribs were successfully obtained. This research work provides a theoretical reference for the extrusion forming process and the die optimization design of such components.
The thin-walled component with I-type longitudinal ribs has complex structure and uneven wall thickness,and it is easy to occur uneven metal flow during extrusion process,which leads to warping deformation of profile. For the above problem,the influences of process parameters such as extrusion speed,initial temperature of blank and initial temperature of die on the extrusion forming effect were studied by finite element analysis software Hyper Xtrude. It is found that the increase of initial temperature of blank makes the metal flow velocity more uniform,while the excessive extrusion speed and initial temperature of die increase the non-uniformity of metal flow velocity.Furthermore,the optimum combination of forming process parameters was obtained with the extrusion speed of 2 mm·s~(-1),the initial temperature of blank of 480 ℃ and the initial temperature of die of 440 ℃ by orthogonal test. Finally,the corresponding extrusion tests were carried out,and the high-precision samples of thin-walled component with I-type longitudinal ribs were successfully obtained. This research work provides a theoretical reference for the extrusion forming process and the die optimization design of such components.
引文
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[14]Zhang Q,Zhang C,Zhao G,et al.Automatic optimization design of a feeder extrusion die with response surface methodology and mesh deformation technique[J].International Journal of Advanced Manufacturing Technology,2017,91(9-12):3181-3193.
[2]吴向红,赵国群,赵新海,等.铝型材挤压成形过程数值模拟的研究现状及发展[J].系统仿真学报,2007,19(5):945-948.Wu X H,Zhao G Q,Zhao X H,et al.Research status and development of aluminum extrusion process simulation[J].Journal of System Simulation,2007,19(5):945-948.
[3]陈浩,赵国群,张存生,等.薄壁空心铝型材挤压过程数值模拟及模具优化[J].机械工程学报,2010,46(24):34-39.Chen H,Zhao G Q,Zhang C S,et al.Numerical simulation of extrusion process and die structure optimization for a hollow aluminum profile with thin wall[J].Journal of Mechanical Engineering,2010,46(24):34-39.
[4]陈广娟,姜国聚,林祖湧.Hyper Xtrude软件在铝型材挤压模具设计中的作用[J].铸造技术,2016,37(5):1040-1042.Chen G J,Jiang G J,Lin Z Y.Key role of Hyper Xtrude software in designing extrusion die for aluminum profile[J].Foundry Technology,2016,37(5):1040-1042.
[5]张驰,曾卫东,李兴无,等.挤压参数对TC16合金紧固件冷挤压过程的影响[J].材料工程,2008,(8):35-39.Zhang C,Zeng W D,Li X W,et al.Effect of extrusion parameters on cold extrusion process of TC16 titanium alloy fastener[J].Journal of Materials Engineering,2008,(8):35-39.
[6]刘立杰,房磊.7075铝合金杯形反挤压成形计算机仿真[J].工具技术,2016,50(7):76-79.Liu L J,Fang L.Computer simulation of backward extrusion process of 7075 aluminum alloy based on orthogonal experiment[J].Tool Engineering,2016,50(7):76-79.
[7]徐磊,赵国群,张存生,等.多腔壁板铝型材挤压过程数值模拟及模具优化[J].机械工程学报,2010,47(24):34-39.Xu L,Zhao G Q,Zhang C S,et al.Numerical simulation of extrusion process and die optimization for aluminum multi-cavity profile[J].Journal of Mechanical Engineering,2010,47(24):34-39.
[8]Chen H,Zhao G Q,Zhang C S,et al.Numerical simulation of extrusion process and die structure optimization for a complex aluminum multicavity wallboard of high-speed train[J].Advanced Manufacturing Processes,2011,26(12):1530-1538.
[9]钟建华,袁志燕,刘艳霞,等.挤压工艺参数对挤压过程影响规律的仿真模拟研究[J].有色金属科学与工程,2015,(3):45-50.Zhong J H,Yuan Z Y,Liu Y X,et al.Numerical simulation of effects of extrusion process parameters on extrusion process[J].Nonferrous Metals Science and Engineering,2015,(3):45-50.
[10]吴向红,赵国群,孙胜,等.挤压速度和摩擦状态对铝型材挤压过程的影响[J].塑性工程学报,2007,14(1):36-41.Wu X H,Zhao G Q,Sun S,et al.The influence of extrusion speed and frictional status on aluminum profile extrusion processes[J].Journal of Plasticity Engineering,2007,14(1):36-41.
[11]Zhang C S,Zhao G Q,Chen Z,et al.Effect of extrusion stem speed on extrusion process for a hollow aluminum profile[J].Materials Science&Engineering B,2012,177(19):1691-1697.
[12]闫洪,夏巨谌,李志刚,等.工艺参数对铝型材挤压变形规律的影响[J].中国有色金属学报,2002,12(6):1154-1161.Yan H,Xia J C,Li Z G,et al.Effect of technological parameters on profile extrusion forming process[J].The Chinese Journal of Nonferrous Metals,2002,12(6):1154-1161.
[13]Lou S M,Wang Y X,Lu S,et al.Optimization of a porthole die for an aluminum profile extrusion based on orthogonal test method[J].International Journal of Engineering Research in Africa,2015,14:49-57.
[14]Zhang Q,Zhang C,Zhao G,et al.Automatic optimization design of a feeder extrusion die with response surface methodology and mesh deformation technique[J].International Journal of Advanced Manufacturing Technology,2017,91(9-12):3181-3193.