低频振动辅助齿轮成形的减摩机理研究
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摘要
为研究低频振动辅助成形过程中被加工工件与模具间的外摩擦对材料成形的影响,通过理论分析,并利用Deform有限元软件对直齿圆柱齿轮进行常规和低频振动冷镦挤成形。结果表明:施加振动后,当凹模的运动方向与坯料的流动方向相同,且凹模的运动速度大于坯料的最大流动速度时,其成形载荷会明显下降,材料流动更均匀,齿形填充效果明显提高。分析其主要原因是在该时间段内摩擦矢量完全反向,坯料向着有利于成形的方向流动。另外,增大振幅或提高频率都会增加摩擦矢量完全反向的总时间,降载程度更明显。
To study the influence of the external friction between the machined workpiece and die on the material forming in the process of low frequency vibration assisted forming,through theoretical analysis,the conventional and low frequency vibration cold upsetting-extruding for spur gear were conducted by Deform finite element simulation. The results show that after appling the vibration,the forming load decreases obviously,the material flow is more uniform,and the filling effect of gear is improved obviously when the moving direction of die is the same as the flowing direction of the blank,and the speed of die is greater than the maximum flow velocity of the blank. The main reason is that the friction vector is completely reversed in this period of time,and the blank flow to the direction which is beneficial to the forming. In addition,increasing the amplitude or raising the frequency can increase the total time that the friction vector is completely reversed,and the decrease of load is greater.
To study the influence of the external friction between the machined workpiece and die on the material forming in the process of low frequency vibration assisted forming,through theoretical analysis,the conventional and low frequency vibration cold upsetting-extruding for spur gear were conducted by Deform finite element simulation. The results show that after appling the vibration,the forming load decreases obviously,the material flow is more uniform,and the filling effect of gear is improved obviously when the moving direction of die is the same as the flowing direction of the blank,and the speed of die is greater than the maximum flow velocity of the blank. The main reason is that the friction vector is completely reversed in this period of time,and the blank flow to the direction which is beneficial to the forming. In addition,increasing the amplitude or raising the frequency can increase the total time that the friction vector is completely reversed,and the decrease of load is greater.
引文
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[15]吴晓,李建军,郑志镇.振动场作用下金属塑性成形机理的研究和应用进展[J].塑性工程学报,2015,22(4):1-7.WU Xiao,LI Jianjun,ZHENG Zhizhen. Research and application progress of metal plastic forming mechanism under vibration field[J]. Journal of Plasticity Engineering,2015,22(4):1-7.
[16]温彤,裴春雷,李昌坤.塑性成形过程的振动应用技术[J].热加工工艺,2009,38(1):114-117.WEN Tong,PEI Chunlei,LI Changkun. Application of vibration in plastic forming process[J]. Hot Working Technology,2009,38(1):114-117.
[2]姜志宏,王宝雨,龚姚腾.在低频振动作用下Q235A钢的拉伸变形行为[J].机械工程材料,2017,41(6):14-16,54.JIANG Zhihong,WANG Baoyu,GONG Yaoteng. Tensile deformation behavior of Q235A steel under low-frequency vibration[J].Materials for Mechanical Engineering,2017,41(6):14-16,54.
[3]梁瑜轩,黎向锋,左敦稳.内螺纹低频振动冷挤压振动加工装置动力学仿真分析[J].振动与冲击,2012,31(22):143-146.LIANG Yuxuan,LI Xiangfeng,ZUO Dunwen. Dynamic simulation for a vibration processing equipment of internalthread formed by cold extrusion based on low frequency vibration[J]. Journal of Vibration and Shock,2012,31(22):143-146.
[4] QI H Q,YUAN J B,XIE T. Investigations on the effects of ultrasonic vibrations in the wire drawing[C]//IEEE International Ultrasonics Symposium Abstract Book. 2008:2134-2137.
[5]高家意,温殿英,李连进.无缝钢管轧制过程的振动稳定性分析[J].天津理工大学学报,2009,25(6):46-48.GAO Jiayi,WEN Dianying,LI Lianjin. Vibration stability analysis of rolling process of seamless steel tube[J]. Journal of Tianjin University of Technology,2009,25(6):46-48.
[6]蔡改贫,徐建波,翁海珊.扭转振动摆动辗压精密成形机理研究[J].锻压技术,2006,31(1):40-42+53.CAI Gaipin,XU Jianbo,WENG Haishan. Research of precision form mechanism by torsion vibro-rotary forging[J]. Forging&Stamping Technology,2006,31(1):40-42+53.
[7] BLAHA F,LANGENECKER B. Dehnung von Zink-Kristallen under ultraschalleinwirkung[J]. Die Naterwissenschaften,1955,42(2):556.
[8]温彤,陈霞.超声振动对轻合金塑性压缩变形过程的影响[J].机械科学与技术,2013,32(2):221-224.WEN Tong,CHEN Xia. Effect of the ultrasonic vibration on the plastic deformation behavior in the compression process of light alloy[J]. Journal of Mechanical Engineering,2013,32(2):221-224.
[9]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 Shengdun,LI Yongyi,FAN Shuqin. Status analysis of plastic technology with ultrasonic vibration[J]. China Mechanical Engineering,2013,24(6):835-840.
[10] KIRCHNER H O K,KROMP W K,PRINZ F B,et al. Plastic deformation under simultaneous cyclic and unidirectional loading at low and ultrasonic frequencies[J]. Materials Science&Engineering,1985,68(2):197-206.
[11]韩清凯,刘树英,闻邦椿.金属材料振动拉伸的实验[J].东北大学学报,2002,(2):170-173.HAN Qingkai,LIU Shuying,WEN Bangchun. Experiment of vibrational stretching of metal materials[J]. Journal of Northeastern University,2002,(2):170-173.
[12]蔡改贫,刘峥,张晖.低频脉冲振动条件下金属成形的体积效应分析[J].锻压技术,2008,33(5):155-159.CAI Gaipin,LIU Zheng,ZHANG Hui. Volume effect analysis of metal deformation with low-frequency pulse vibration[J]. Forging&Stamping Technology,2008,33(5):155-159.
[13]蔡改贫,翁海珊,姜志宏.振动拉拔的非局部摩擦问题的近似求解及表面效应初探[J].机械工程学报,2006,42(8):190-194.CAI Gaipin,WENG Haishan,JIANG Zhihong. Approximate solution and surface effect of non-local friction problem in vibration drawing[J]. Chinese Journal of Mechanical Engineering,2006,42(8):190-194.
[14]何勍,闻邦椿.振动塑性加工的进展及若干问题[J].辽宁工学院学报,1999,19(4):5-9.HE Qing,WEN Bangchun. The development of vibration plasticity processing and some problems[J]. Journal of Liaoning Institute of Technology,1999,19(4):5-9.
[15]吴晓,李建军,郑志镇.振动场作用下金属塑性成形机理的研究和应用进展[J].塑性工程学报,2015,22(4):1-7.WU Xiao,LI Jianjun,ZHENG Zhizhen. Research and application progress of metal plastic forming mechanism under vibration field[J]. Journal of Plasticity Engineering,2015,22(4):1-7.
[16]温彤,裴春雷,李昌坤.塑性成形过程的振动应用技术[J].热加工工艺,2009,38(1):114-117.WEN Tong,PEI Chunlei,LI Changkun. Application of vibration in plastic forming process[J]. Hot Working Technology,2009,38(1):114-117.