基于超声振动的镁合金双锥件颗粒介质成形工艺
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摘要
针对结构复杂且具有局部小特征的镁合金双锥件成形制造难的问题,提出一种超声振动辅助颗粒介质成形新工艺。基于有限元软件ABAQUS平台,从超声振动影响板材-模具及板材-介质之间摩擦因数的角度,建立AZ31B镁合金双锥形件的VGMF仿真模型,探讨不同振幅及压边间隙等工业参数对镁合金板材成形性能的影响。并运用有限元分析结果开展相应条件下的镁合金双锥形件VGMF相关试验,对模拟结果进行有效验证,证明该新工艺的适用性。结果表明:当压边间隙为1.25倍板厚时,板材具有较高的极限拉深比;超声振动能够有效降低成形力,改善壁厚均匀度,提高板料的成形极限,VGMF工艺为镁合金板材成形复杂截面零件提供新方法。
The vibration granules medium forming(VGMF) was proposed to solve the manufacturing problem of a AZ31 B magnesium alloy biconical specimen with some small local complex structures. The VGMF process simulation model of AZ31 B magnesium alloy biconical parts was established with ABAQUS from the effect of vibration on the friction coefficients of sheet-die and sheet-medium, and the influences of different amplitudes and blank-holder gaps on magnesium alloy sheet forming properties were discussed. The accuracy of simulation results was proved by the VGMF test of AZ31 B biconical parts, and the applicability of the new process was proven. The results show that the ultrasonic vibration can reduce the forming force, keep the uniformity of the thickness, and improve the forming limit of the sheet metal, and when the blank-holder gap is 1.25 times of sheet thickness, the magnesium alloy sheet has a higher limit drawing ratio(LDR). VGMF provides a new method for forming complex cross-section parts of magnesium alloy sheet.
The vibration granules medium forming(VGMF) was proposed to solve the manufacturing problem of a AZ31 B magnesium alloy biconical specimen with some small local complex structures. The VGMF process simulation model of AZ31 B magnesium alloy biconical parts was established with ABAQUS from the effect of vibration on the friction coefficients of sheet-die and sheet-medium, and the influences of different amplitudes and blank-holder gaps on magnesium alloy sheet forming properties were discussed. The accuracy of simulation results was proved by the VGMF test of AZ31 B biconical parts, and the applicability of the new process was proven. The results show that the ultrasonic vibration can reduce the forming force, keep the uniformity of the thickness, and improve the forming limit of the sheet metal, and when the blank-holder gap is 1.25 times of sheet thickness, the magnesium alloy sheet has a higher limit drawing ratio(LDR). VGMF provides a new method for forming complex cross-section parts of magnesium alloy sheet.
引文
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[9]WEN Tong,GAO Rui,CHEN Xia.Influence of high frequency vibration on deep drawing process of AZ31 sheet at room temperature[J].Journal of Shanghai Jiao Tong University(Science),2012,17(4):456-460.
[10]CHEN H,GüNER A,KHALIFA N B,TEKKAYA A E.Granular media-based tube press hardening[J].Journal of Materials Processing Technology,2016,228:145-159.
[11]CAO Miao-yan,ZHAO Chang-cai,DONG Guo-jiang,YANG Sheng-fu.Instability analysis on the free deformation zone in forming process of cylindrical parts with hot granule medium[J].Transactions of Nonferrous Metals Society of China,2016,26(8):2188-2196.
[12]GRüNER M,MERKLEIN M.Numerical simulation of hydro forming at elevated temperatures with granular material used as medium compared to the real part geometry[J].International Journal of Material Forming,2010,3(1):279-282.
[13]李鹏亮,张志,曾元松.钛合金机头罩固体颗粒介质成形工艺研究[J].锻压技术,2012,37(5):60-63.LI Peng-liang,ZHANG Zhi,ZENG Yuan-song.Study on titanium alloy spinner based on solid granules medium forming[J].Forging&Stamping Technology,2012,37(5):60-63.
[14]赵升吨,李泳峄,范淑琴.超声振动塑性加工技术的现状分析[J].中国机械工程,2013,24(6):835-840.ZHAO Sheng-dun,LI Yong-ze,FAN Shu-qin.Status analysis of plastic processing technology with ultrasonic vibration[J].China Mechanical Engineering,2013,24(6):835-840.
[15]BLAHA F,LANGENECKER B.Elongation of zinc monocrystals under ultrasonic action[J].Die Natur Wissenschafen,1955,42(20):556-556.(in German)
[16]PASIERB A,WOJNAR A.An experimental investigation of deep-drawing process of thin-walled products with utilization of ultrasonic vibrations[J].Journal of Materials Processing Technology 1992,34(1/4):489-494.
[17]谢涛,齐海群,张俊.超声振动拉丝实验研究[J].中国机械工程,2006,17(3):224-226.XIE Tao,QI Hai-qun,ZHANG Jun.Experimental research on wire drawing with ultrasonic vibration[J].China Mechanical Engineering,2006,17(3):224-226.
[18]CAO Miao-yan,PENG Ya-xin,ZHAO Chang-cai,DONGGuo-jiang,DU Bing.Frictional characteristics of granular system under high pressure[J].Journal of Central South University,2016,23(5):1132-1141.
[2]郜瑞,温彤,季筱玮,张文城.镁合金板材拉深工艺的研究与进展[J].热加工工艺,2012,41(5):30-32.GAO Rui,WEN Tong,JI Xiao-wei,ZHANG Wen-cheng.Research and development of drawing technology for magnesium alloy[J].Hot Working Technology,2012,41(5):30-32.
[3]申利权,杨旗,靳丽,董杰.AZ31B镁合金在高应变速率下的热压缩变形行为和微观组织演变[J].中国有色金属学报,2014(9):2195-2204.SHEN Li-quan,YANG Qi,JIN Li,DONG Jie.Deformation behavior and microstructure transformation of AZ31B Mg alloy under high strain rate compression[J].The Chinese Journal of Nonferrous Metals,2014(9):2195-2204.
[4]张士宏,宋广胜,宋鸿武,程明.镁合金板材温热变形机理及温热成形技术[J].机械工程学报,2012,48(18):28-34.ZHANG Shi-hong,SONG Guang-sheng,SONG Hong-wu,CHENG Ming.Deformation mechanism and warm forming technology for magnesium alloys sheets[J].Journal of Mechanical Engineering,2012,48(18):28-34.
[5]VIEHWEGER B,RICHTER G,DüRING M,KARABET A,SVIRIDOV A,HARTMANN H,RICHTER U.Hydromechanisches tiefziehen und hochdruckblechumformung als verfahren zur herstellung komplexer bauteile aus magnesiumfeinblechen des typs AZ31B-0[J].Materialwissenschaft Und Werkstofftechnik,2004,35(7):440-446.(in German)
[6]LEE S,CHEN Y H,WANG J Y.Isothermal sheet formability of magnesium alloy AZ31 and AZ61[J].Journal of Materials Processing Technology,2002,124:19-24.
[7]ANTONISWAMY A R,CARPENTER A J,CARTER J T,JRL G H,TALEFF E M.Forming-limit diagrams for magnesium AZ31B and ZEK100 alloy sheets at elevated temperatures[J].Journal of Materials Engineering&Performance,2013,22(11):3389-3397.
[8]赵长财,李晓丹,董国疆,王银思.板料固体颗粒介质成形新工艺及其数值模拟[J].机械工程学报,2009,45(6):211-215.ZHAO Chang-cai,LI Xiao-dan,DONG Guo-jiang,WANGYin-si.Solid granules medium forming technology and its numerical simulation[J].Journal of Mechanical Engineering,2009,45(6):211-215.
[9]WEN Tong,GAO Rui,CHEN Xia.Influence of high frequency vibration on deep drawing process of AZ31 sheet at room temperature[J].Journal of Shanghai Jiao Tong University(Science),2012,17(4):456-460.
[10]CHEN H,GüNER A,KHALIFA N B,TEKKAYA A E.Granular media-based tube press hardening[J].Journal of Materials Processing Technology,2016,228:145-159.
[11]CAO Miao-yan,ZHAO Chang-cai,DONG Guo-jiang,YANG Sheng-fu.Instability analysis on the free deformation zone in forming process of cylindrical parts with hot granule medium[J].Transactions of Nonferrous Metals Society of China,2016,26(8):2188-2196.
[12]GRüNER M,MERKLEIN M.Numerical simulation of hydro forming at elevated temperatures with granular material used as medium compared to the real part geometry[J].International Journal of Material Forming,2010,3(1):279-282.
[13]李鹏亮,张志,曾元松.钛合金机头罩固体颗粒介质成形工艺研究[J].锻压技术,2012,37(5):60-63.LI Peng-liang,ZHANG Zhi,ZENG Yuan-song.Study on titanium alloy spinner based on solid granules medium forming[J].Forging&Stamping Technology,2012,37(5):60-63.
[14]赵升吨,李泳峄,范淑琴.超声振动塑性加工技术的现状分析[J].中国机械工程,2013,24(6):835-840.ZHAO Sheng-dun,LI Yong-ze,FAN Shu-qin.Status analysis of plastic processing technology with ultrasonic vibration[J].China Mechanical Engineering,2013,24(6):835-840.
[15]BLAHA F,LANGENECKER B.Elongation of zinc monocrystals under ultrasonic action[J].Die Natur Wissenschafen,1955,42(20):556-556.(in German)
[16]PASIERB A,WOJNAR A.An experimental investigation of deep-drawing process of thin-walled products with utilization of ultrasonic vibrations[J].Journal of Materials Processing Technology 1992,34(1/4):489-494.
[17]谢涛,齐海群,张俊.超声振动拉丝实验研究[J].中国机械工程,2006,17(3):224-226.XIE Tao,QI Hai-qun,ZHANG Jun.Experimental research on wire drawing with ultrasonic vibration[J].China Mechanical Engineering,2006,17(3):224-226.
[18]CAO Miao-yan,PENG Ya-xin,ZHAO Chang-cai,DONGGuo-jiang,DU Bing.Frictional characteristics of granular system under high pressure[J].Journal of Central South University,2016,23(5):1132-1141.