摘要
镀锌板是在普通钢板的表面附着一层锌层,使其具有良好的防腐蚀性能。现在已经越来越多的应用在汽车、建筑、家电等行业。但由于镀层与基体存在显著的不同特性,因此镀锌板的冲压成形特性与普通钢板相比存在着很大的不同,同时镀层在冲压成形过程中还会出现粉末化剥离、片状脱落、磨损、破裂、鼓包等形式失效。随着生产与技术的发展,普通钢板的冲压成形技术已经日趋成熟,而对于镀锌板的成形性研究以前往往只局限在镀层的制备和使用上。
板料在冲压过程中的摩擦特性相当复杂,同时摩擦对于板料冲压成形的成败与否具有很大的影响,而现在对于板料冲压成形过程中摩擦问题的研究还没有形成一个统一的结论。
因此基于以上两点,研究镀锌板在冲压过程中的摩擦特性具有很好的理论意义和现实意义。
本文从板料冲压成形的接触和摩擦理论分析入手,对镀锌板进行杯突试验和销盘摩擦试验,随后通过运用冲压软件对杯突试验进行模拟,分析了镀锌板在冲压成形过程中的摩擦特性。具体研究工作如下。
(1)通过对镀锌板进行杯突试验分析了冲压速度和润滑条件对镀锌板杯突值的影响。随后又对镀锌板进行了销盘摩擦试验,并运用正交分析的方法,分析了速度、正压力、镀层对摩擦系数的影响水平。
(2)运用固连失效接触建立镀锌板模型,并在此模型的基础上模拟了镀锌板杯突成形过程。模拟结果可以看出镀层在成形过程中的变化,因此有助于分析镀层在镀锌板冲压过程中的影响。随后通过模拟结果分析了摩擦系数对镀锌板的冲压成形影响。
(3)运用有限元模拟与杯突试验相结合的方法反求出镀锌板成形过程中的摩擦系数。根据模拟结果分析了冲压速度和润滑条件对摩擦系数的影响以及摩擦系数与镀锌板杯突值之间的相互影响关系。
Zinc coating in the surface of ordinary sheet called zinc-coated sheet, it has good corrosion resistance and was used in the automotive, construction, household appliances industry. However, zinc coating and basic sheet have significantly different characteristics, so compare with ordinary sheet, it has great different in stamping features. At the same time, in the process of stamping, powdered peel, flake off, wear, broken, drum and other forms of package failure will appear. With the development of production and technology, stamping technology of ordinary sheet has matured, but the research of zinc-coated sheet just confined to the preparation and use of zinc coating.
The friction of sheet is complex in the process of stamping and it has great impact on sheet forming of success or failure. But the unified conclusion has not obtained in the study of friction in the process of sheet forming.
Therefore, do researches in friction of zinc-coated sheet in the process of stamping has good theoretical and practical significance.
This article analysis the contact and the friction theoretic of sheet stamping forming and do the pin-on-disk friction test and the cupping test with zinc-coated sheet. Then use software to simulate cupping forming to analysis the friction property of zinc-coated sheet on the stamping forming. The following are the specific of research:
(1) Analysis the impact of stamping velocity and lubrication conditions on the cupping value of zinc-coated sheet by cupping test. Then do the pin-on-disk friction test with zinc-coated sheet and analysis the effect of levels of contact pressure、stamping velocity and zinc coating on the frictional coefficient of zinc-coated sheet by orthogonal test and variance analysis .
(2) Tiebreak contact was used to establish the model of zinc-coated sheet and simulate the cupping test by stamping software under this model. By the results could show the movement of zinc coating in the process of forming, so it has benefit to analysis the impact of zinc coating on the process of stamping. Analyses the effect of frictional coefficient on the zinc-coated sheet process stamping forming by simulate results.
(3) With combine the finite element simulation and the cupping test to reverse obtained the friction coefficient in process of zinc-coated sheet forming. Analyses the impact of stamping velocity and lubrication conditions on the friction coefficient and the relationship between friction coefficient and cupping value by simulate results.
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