摘要
管材翻转成形工艺是由冲压翻边、扩口和缩口等传统工艺发展起来的一种新的特种成形工艺。利用管材翻转成形技术制造零件,具有工艺简单、工序少、成本低、质量好等优点,甚至可以生产出用其它冲压方法难以到得的零件。但在成形过程中容易出现轴向受压失稳、管端撕裂失稳等形式的失效,成形性较差;另外,由于用锥形模和圆角模翻管过程中存在无约束的自由变形,所成形零件的尺寸精度较低。本文针对目前存在的一些问题,结合数值模拟技术,对管材翻转成形进行了研究。
首先,在参考大量国内外技术资料的基础上,探讨了管材翻转成形的基本理论、常见翻管模特点、管材翻转成形的失稳方式等问题,并简单分析了轴向受压失稳和管端撕裂失稳两种常见失稳方式。
其次,从理论上对用锥形模、圆角模、槽形模等常见翻管模进行管翻转成形的过程进行了深入研究,分析了各种翻管模翻管的变形过程以及主要参数对成形过程的影响,得出了各参数对成形过程的一些影响规律。
在上述研究的基础上,针对传统翻管模存在的缺陷,本文提出了“助推式”翻管模结构,并模拟了其翻管变形过程,分析了各参数对成形过程的影响,初步总结了一些成形的规律。该“助推式”翻管模与传统管材翻转成形结构比较,不仅提高了翻管制件的几何尺寸精度,也在很大程度上改善了管坯的可成形性。
本文的研究成果对管材翻转成形技术的发展,拓宽管材翻转成形技术的应用范围具有重要意义。
Tube inversion is a special forming processing that was developed from traditional tube processing, such as flange in stamping, flaring and necking. Tube inversion has many advantages, it’s simple and low cost. It even can make some complicated parts which are difficult to be manufactured by any other stamping technology. At the same time,forming performance is not very good. Some inactivation forms,such as axial destabilization in compression and end tearing destabilization,may happen during the forming process. Forming with conical die and fillet die has a special condition of dieless constrained and free forming,so the forming part has low dimension accuracy. Toward this situation,an investigation on tube inversion forming has been carried on by using the numerical simulation technology.
First, based on lots of reference,this dissertation introduces the basic theories of tube inversion forming,features of many common tube inversion die, failure forms of tube inversion and simply analyzes two common failure forms axial destabilization in compression and end tearing destabilization.
Second, further study has been carried out toward forming with conical die, fillet die and channel die. Forming process of above tube inversion dies has been discussed. The influence law of some main parameters in forming process has been obtained by analyzing these parameters’impact to forming process.
Based on the study above,for the defects of traditional process, an aid-push die has been proposed and numerical simulation of its forming process has been done. Then some influence law of the parameters has been achieved. Compared with other common die, aid-push die improves the dimension accuracy of the components and the forming performance of tube stock.
The achievement in this dissertation will play an important part in development of tube inversion forming technology and enlarging the application of this technology.
引文
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