基于Deform和响应曲面法的钢丝拉拔工艺优化
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摘要
目的对钢丝拉拔过程的成形质量和拉拔力同时进行优化。方法通过Deform-3D软件建立钢丝拉拔第一道次的有限元分析模型,并验证其可靠性。结合建立的有限元模型,采用正交试验设计,寻找钢丝拉拔过程的显著性影响因素,再以显著性因素为变量,以成形质量指标(文中定义为不均匀系数N)和拉拔力P为响应,建立响应曲面模型,对工艺参数进行优化。结果通过正交试验设计分析发现,模具半锥角和压缩率既是不均匀系数N的显著性影响因素,又是拉拔力P的显著性影响因素;通过分析建立的响应曲面模型发现,单独优化一个指标时,会劣化另一个指标,综合考虑两个指标,得到的较优的工艺参数为模具半锥角5°,压缩率17.65%,此时不均匀系数N为0.247,拉拔力P为2593.77N。结论经过验证,建立的有限元模型和响应曲面模型均具有可靠性,可用于钢丝拉拔工艺的研究和优化。
The work aims to optimize both the forming quality and the drawing force of the wire drawing process. A finite element analysis model of the first pass of steel wire drawing was established with software Deform-3 D to verify its reliability.Based on the finite element model, the orthogonal test design was carried out to find the significant influencing factors of the wire drawing process, and then the response surface model was established to optimize the process parameters with the significant factors as variables, the forming quality index(defined as nonuniformity coefficient N) and the drawing force P as response.It was found through the orthogonal test that the half die angle and compression ratio were not only the significant influence factors of the nonuniformity coefficient N, but also the significant influence factors of the drawing force P. By analyzing the response surface model, it was found that when one index was optimized alone, another index would be degraded. Taking two indexes into account, the better process parameters were the half die angle was 5° and the compression ratio was 17.65%. At that time, the nonuniformity coefficient N was 0.247 and the drawing force P was 2593.77 N. After verification, the finite element model and response surface model are both reliable and can be used for the study and optimization of steel wire drawing process.
The work aims to optimize both the forming quality and the drawing force of the wire drawing process. A finite element analysis model of the first pass of steel wire drawing was established with software Deform-3 D to verify its reliability.Based on the finite element model, the orthogonal test design was carried out to find the significant influencing factors of the wire drawing process, and then the response surface model was established to optimize the process parameters with the significant factors as variables, the forming quality index(defined as nonuniformity coefficient N) and the drawing force P as response.It was found through the orthogonal test that the half die angle and compression ratio were not only the significant influence factors of the nonuniformity coefficient N, but also the significant influence factors of the drawing force P. By analyzing the response surface model, it was found that when one index was optimized alone, another index would be degraded. Taking two indexes into account, the better process parameters were the half die angle was 5° and the compression ratio was 17.65%. At that time, the nonuniformity coefficient N was 0.247 and the drawing force P was 2593.77 N. After verification, the finite element model and response surface model are both reliable and can be used for the study and optimization of steel wire drawing process.
引文
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[2]钟海平.冷拔珠光体钢丝力学性能分析及成形工艺优化[D].重庆:重庆大学,2014.ZHONG Hai-ping.Mechanical Performance Analysis and Forming Process Optimization of Cold-drawn Pearlitic Wires[D].Chongqing:Chongqing University,2014.
[3]徐戊矫,王凯庆,邹明平,等.基于数值模拟的冷拉钢丝表面Ra的优化[J].材料科学与工艺,2012,20(3):7-12.XU Wu-jiao,WANG Kai-qing,ZOU Ming-ping,et al.Optimization of Surface Accuracy Ra for the Cold Drawn Steel Wire Based on Numerical Simulation[J].Materials Science and Technology,2012,20(3):7-12.
[4]毛小玲,苏岚,米振莉.基于有限元模拟的钢丝拉拔过程变形均匀性分析[C]//第十届中国钢铁年会暨第六届宝钢学术年会论文集II,上海,2015.MAO Xiao-ling,SU Lan,MI Zhen-li.Deformation Uniformity Analysis of Wire Drawing Process Based on Finite Element Simulation[C]//Proceedings II of the Tenth China Iron and Steel Annual Conference and the Sixth Baosteel Academic Annual Conference,Shanghai,2015.
[5]张磊.约束优化算法的关键技术研究及应用[D].哈尔滨:哈尔滨工程大学,2016.ZHANG Lei.Key Technology Research and Application of Constrained Optimization Algorithm[D].Harbin:Harbin Engineering University,2016.
[6]梁静,宋慧,瞿博阳.多目标优化在路径优化中的应用[J].计算机仿真,2014,31(4):364-368.LIANG Jing,SONG Hui,QU Bo-yang.Application of Multi-objective Optimizer in Path Planning[J].Computer Simulation,2014,31(4):364-368.
[7]梁静,宋慧,王龙,等.多目标优化在中央空调节能优化系统中的应用[J].计算机仿真,2015,32(6):302-307.LIANG Jing,SONG Hui,WANG Long,et al.Application of Multi-Objective Optimization in Energy Saving for Air Conditioning System[J].Computer Simulation,2015,32(6):302-307.
[8]ABBAS A R,LI M H,TAI K C.Optimizing SUS 304Wire Drawing Process by Grey Relational Analysis Utilizing Taguchi Method[J].Journal of University of Science and Technology Beijing,2008,15(6):714-722.
[9]SAS-BOCA I M,TINTELECAN M,POP M,et al.The Wire Drawing Process Simulation and the Optimization of Geometry Dies[J].Procedia Engineering,2017,181:187-192.
[10]黄帅,宋仁伯,杨富强,等.水箱拉丝机拉丝过程的有限元模拟仿真分析[J].武汉科技大学学报,2012(6):447-451.HUANG Shuai,SONG Ren-bo,YANG Fu-qiang,et al.Finite Element Simulation Analysis of Drawing Process by Wet Drawing Machine[J].Journal of Wuhan University of Science and Technology,2012(6):447-451.
[11]胡建军,李小平.DEFORM-3D塑性成形CAE应用教程[M].北京:北京大学出版社,2011.HU Jian-jun,LI Xiao-ping.Application Course of DEFORM-3D Plastic Forming CAE[M].Beijing:Peking University Press,2011.
[12]费洪旗.镁合金丝材拉拔成形及数值模拟研究[D].扬州:扬州大学,2017.FEI Hong-qi.Drawing and Numerical Simulation of Magnesium Alloy Wire[D].Yangzhou:Yangzhou University,2017.
[13]徐效谦,阴绍芬.特殊钢钢丝[M].北京:冶金工业出版社,2005.XU Xiao-qian,YIN Shao-fen.Special Steel Wire[M].Beijing:Metallurgical Industry Press,2005.
[14]李兵,刘奎武,高鹏,等.基于响应曲面法的传动带成形工艺参数优化[J].锻压技术,2017,42(2):189-192.LI Bing,LIU Kui-wu,GAO Peng,et al.Optimization on Process Parameters of Leaf Spring Based on Response Surface Method[J].Forging&Stamping Technology,2017,42(2):189-192.
[15]潘和勇,樊文欣,王欣,等.基于响应曲面法的筒形件强力旋压回弹量研究[J].塑性工程学报,2018,25(5):148-152.PAN He-yong,FAN Wen-xin,WANG Xin,et al.Study on Springback of Power Spinning Barrel Part Based on Response Surface Method[J].Journal of Plasticity Engineering,2018,25(5):148-152.
[16]何为,唐斌,薛卫东.优化试验设计方法及数据分析[M].北京:化学工业出版社,2012.HE Wei,TANG Bin,XUE Wei-dong.Optimizing Test Design Method and Data Analysis[M].Beijing:Chemical Industry Press,2012.
[17]徐洁.基于响应曲面法的激光切割工艺参数的优化研究[D].武汉:华中科技大学,2012.XU Jie.Study on Optimization of Laser Cutting Parameters with Response Surface Methodology[D].Wuhan:Huazhong University of Science and Technology,2012.