一种新辊型的增量滚压成形过程仿真
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摘要
增量滚压成形工艺采用渐进成形的方式在板材表面滚压微沟槽结构,在该工艺原理的基础上,将传统的单一辊型设计为4种不同的辊型。采用有限元软件对新辊型的增量滚压成形过程进行数值模拟,与传统辊型的成形效果进行对比,并分析了新辊型滚压时工件材料流动的特点。结果表明:滚压完成后,新辊型与传统辊型成形的微沟槽高度相等,但后者成形工件端部的堆积量小于前者;在此成形过程中,采用新辊型的辊轮承受的成形载荷更小;通过对工件的速度场、应力场以及应变场的分析,得到工件材料在成形过程中的流动特点,为今后辊轮的优化设计提供了有效的参考。
Incremental rolling technology is a process of rolling micro-groove structure on sheet metal surface by incremental forming.Based on the principle of the process,the traditional single roller profile was designed into four kinds of roller profile,and the incremental rolling process of the new roller profile was simulated by finite element software. Then,the forming quality of the new roller profile was compared with that of the traditional roller profile,and the material flow characteristics of workpiece during the rolling process of the new roller profile were analyzed. The results show that the micro-groove height of the new roller profile is equal to that of the traditional roller profile after rolling,but the accumulation at the end of workpiece formed by the latter is less than that of the former. However,the forming load of the new roller profile is smaller. Furthermore,the flow characteristics of workpiece material during the forming process are obtained by the analysis of the velocity field,equivalent stress field and strain field of workpiece,which provides an effective reference for the optimization design of roller in the future.
Incremental rolling technology is a process of rolling micro-groove structure on sheet metal surface by incremental forming.Based on the principle of the process,the traditional single roller profile was designed into four kinds of roller profile,and the incremental rolling process of the new roller profile was simulated by finite element software. Then,the forming quality of the new roller profile was compared with that of the traditional roller profile,and the material flow characteristics of workpiece during the rolling process of the new roller profile were analyzed. The results show that the micro-groove height of the new roller profile is equal to that of the traditional roller profile after rolling,but the accumulation at the end of workpiece formed by the latter is less than that of the former. However,the forming load of the new roller profile is smaller. Furthermore,the flow characteristics of workpiece material during the forming process are obtained by the analysis of the velocity field,equivalent stress field and strain field of workpiece,which provides an effective reference for the optimization design of roller in the future.
引文
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[2]杨辉,张彬,张利鹏.微结构功能表面的应用及制造[J].航空精密制造技术,2015,51(5):1-6Yang H,Zhang B,Zhang L P.Application and manufacture of microstructure function surface[J].Aviation Precision Manufacturing Technology,2015,51(5):1-6.
[3]Hirt G,Thome M.Rolling of functional metallic surface structures[J].CIRP Annals-Manufacturing Technology,2008,57(1):317-320.
[4]Hirt G,Thome M.Large area rolling of function almetallic micro structures[J].Production Engineering,2007,1(4):351-356.
[5]Zhou R,Cao J,Ehmann K,et al.An investigation on deformation-based surface texturing[J].Journal of Manufacturing Science and Engineering,2011,133(6):613-619.
[6]Lu B,Meng W J.Roll molding of microchannel arrays on Al and Cu sheet metals:A method for high-throughput manufacturing[J].Journal of Micro and Nano-Manufacturing,2014,2(1):007-011.
[7]Gao Z Y,Peng L F,Yi P Y,et al.Grain and geometry size effects on plastic deformation in roll-to-plate micro/meso-imprinting process[J].Journal of Materials Processing Technology,2015,219(5):28-41.
[8]高照阳,彭林法,易培云,等.微细辊对平板滚压成形工艺建模与尺度效应分析[J].机械工程学报,2013,49(6):179-186.Gao Z Y,Peng L F,Yi P Y,et al.Modeling and size effect analysis of micro/meso roll-to-plate imprinting process[J].Journal of Mechanical Engineering,2013,49(6):179-186.
[9]王博.平面板材表面滚压成形微沟槽数值模拟研究[D].吉林:吉林大学,2015.Wang B.Numerical Simulation Research of Rolling Microgroove on Surface of Flat Sheet Metal[D].Jilin:Jilin University,2015.
[10]王传果.板材表面微沟槽滚压成形工艺研究[D].吉林:吉林大学,2016.Wang C G.Study on Roll Forming Grooves on the Surface of Sheet Metal[D].Jilin:Jilin University,2016.
[11]Klocke F,Feldhaus B,Mader S.Development of an incremental rolling process for the production of defined riblet surface structures[J].Production Engineering,2007,1(3):233-237.
[12]Terhorst M,Trauth D,Klocke F.Riblet rolling on Ti6Al4V compressor blades[J].Springer Berlin Heidelberg,2015,(5):245-250.
[13]Hergt A,Hage W,Grund S,et al.Riblet application in compressors:Towards efficient blade design[J].Journal of Turbomachinery,2014,137(11):106-110.
[14]雷玉成,汪建敏,贾志宏.金属材料成型原理[M].北京:化学工业出版社,2006.Lei Y C,Wang J M,Jia Z H.Forming Principle of Metal Materials[M].Beijing:Chemical Industry Publishing House,2006.