AZ31镁合金型材张力绕弯工艺研究
|
摘要
在航空、航天、交通运输、军事器械等领域,型材做为重要的结构材料得到了越来越广泛的应用,同时对材料提出了轻量化、可回收、抗电磁干扰等新的要求。AZ31镁合金有着许多独特的优点,但是室温下塑性差,限制了AZ31镁合金的应用,使得它的潜力远远没有完全发挥。目前镁合金塑性成形技术仍处于实验研发阶段,而镁合金型材张力绕弯工艺的研究是变形镁合金研究的一个重要方向。本文设计了液压式张力绕弯实验机,进行了AZ31镁合金型材张力绕弯实验与有限元模拟。
本文提出了一种型材绕弯过程中利用张力补偿回弹的工艺方法,设计了液压式张力绕弯实验设备与在线信息采集系统。建立了AZ31镁合金型材张力绕弯有限元数学模型。通过型材张力绕弯有限元模拟,确定了镁合金型材张力绕弯成形的合理工艺参数,分析了工艺参数对型材张力绕弯成形质量的影响。
完成了AZ31镁合金型材张力绕弯工艺实验。通过张力绕弯实验研究分析了型材变形区横截面的尺寸变化及金属流动规律,分析了弯曲角度、温度、预拉伸量与回弹角度之间的关系。实验表明温度对回弹影响程度有限,随着温度的升高回弹角度降低,弯曲角度和预拉伸量对回弹角度影响显著。
通过均匀实验设计,采用逐步回归法,得到了能够表明弯曲角度、温度、预拉伸量三者与回弹角度关系的回归方程,通过实验验证了回归方程的可行性,并提出了进一步完善回归方程的研究方法。
In aviation, aerospace, transportation, military equipment and other fields, profiles as an important structural material have been more and more widely used, while the material made lightweight, recyclable, anti-electromagnetic interference and other requirements. AZ31 magnesium alloy has many unique advantages, but its poor room-temperature plasticity limits the application of AZ31 magnesium alloy and makes its potential not fully applied. Plastic forming technology of magnesium alloys is currently still in the experimental research and development stage, while the magnesium alloy tension rotation bending processing of wrought magnesium alloys is an important direction. In this paper, by using self-made hydraulic profiles tension rotation bending machine, combined with tension rotation bending finite element simulation of AZ31 magnesium alloy profiles, experimental research of tension rotation bending forming processing on the AZ31 magnesium alloy profiles is studied.
This paper puts forward a processing method of profiles rotation bending, which could compensate springback for the use of tension rotation bending processing. And the hydraulic tension rotation bending equipment and online information collection systems were designed. AZ31 magnesium alloy finite element mathematical model of profiles tension rotation bending was created. Through finite element simulation of profiles tension rotation bending, the reasonable processing parameters of the magnesium alloy profiles tension rotation bending were determined, the effect of processing parameters on the profiles quality of tension rotation bending forming were analysised.
AZ31 magnesium alloy profiles tension rotation bending processing experiment was completed.Through the tension rotation bending experimental research, the deformation zone of profiles cross-sectional size changes and metal flow laws were analysised, and the bending angle, temperature, pre-stretching value and the relationship between the springback angle were analysised. Experimental results showed that the temperature changing impact finitely on the springback angle, springback angle was decreased with the temperature increasing, bending angle and pre-stretching value were significant impact on the springback angle.
Through the uniform design of experiments and using stepwise regression method, it has been able to obtained the springback angle of the regression equation which related to bending angle, temperature, and pre-stretch value. Experiments showed the feasibility of the regression equation and proposed amendments for the equation of research methods.
本文提出了一种型材绕弯过程中利用张力补偿回弹的工艺方法,设计了液压式张力绕弯实验设备与在线信息采集系统。建立了AZ31镁合金型材张力绕弯有限元数学模型。通过型材张力绕弯有限元模拟,确定了镁合金型材张力绕弯成形的合理工艺参数,分析了工艺参数对型材张力绕弯成形质量的影响。
完成了AZ31镁合金型材张力绕弯工艺实验。通过张力绕弯实验研究分析了型材变形区横截面的尺寸变化及金属流动规律,分析了弯曲角度、温度、预拉伸量与回弹角度之间的关系。实验表明温度对回弹影响程度有限,随着温度的升高回弹角度降低,弯曲角度和预拉伸量对回弹角度影响显著。
通过均匀实验设计,采用逐步回归法,得到了能够表明弯曲角度、温度、预拉伸量三者与回弹角度关系的回归方程,通过实验验证了回归方程的可行性,并提出了进一步完善回归方程的研究方法。
In aviation, aerospace, transportation, military equipment and other fields, profiles as an important structural material have been more and more widely used, while the material made lightweight, recyclable, anti-electromagnetic interference and other requirements. AZ31 magnesium alloy has many unique advantages, but its poor room-temperature plasticity limits the application of AZ31 magnesium alloy and makes its potential not fully applied. Plastic forming technology of magnesium alloys is currently still in the experimental research and development stage, while the magnesium alloy tension rotation bending processing of wrought magnesium alloys is an important direction. In this paper, by using self-made hydraulic profiles tension rotation bending machine, combined with tension rotation bending finite element simulation of AZ31 magnesium alloy profiles, experimental research of tension rotation bending forming processing on the AZ31 magnesium alloy profiles is studied.
This paper puts forward a processing method of profiles rotation bending, which could compensate springback for the use of tension rotation bending processing. And the hydraulic tension rotation bending equipment and online information collection systems were designed. AZ31 magnesium alloy finite element mathematical model of profiles tension rotation bending was created. Through finite element simulation of profiles tension rotation bending, the reasonable processing parameters of the magnesium alloy profiles tension rotation bending were determined, the effect of processing parameters on the profiles quality of tension rotation bending forming were analysised.
AZ31 magnesium alloy profiles tension rotation bending processing experiment was completed.Through the tension rotation bending experimental research, the deformation zone of profiles cross-sectional size changes and metal flow laws were analysised, and the bending angle, temperature, pre-stretching value and the relationship between the springback angle were analysised. Experimental results showed that the temperature changing impact finitely on the springback angle, springback angle was decreased with the temperature increasing, bending angle and pre-stretching value were significant impact on the springback angle.
Through the uniform design of experiments and using stepwise regression method, it has been able to obtained the springback angle of the regression equation which related to bending angle, temperature, and pre-stretch value. Experiments showed the feasibility of the regression equation and proposed amendments for the equation of research methods.
引文
[1]徐义,李落星,李光耀,等.型材弯曲工艺的现状及发展前景[J].塑性工程学报, 2008,15(3) :61-70
[2]肖盼,刘天模,姜丹. AZ31镁合金的研究进展[J].重庆大学学报(自然科学版), 2006,29(11):81-84
[3]王里进. AZ31镁合金板材的塑性加工成形研究[D].重庆:重庆大学,2006
[4] Allwood J. M. A Structured Search for New Metal Forming Processes[C]. The 9th International Conference on Technology of Plasticity, 2008
[5] Williams J. C., Starke E. A., Jr. Progress in structural materials for aerospace systems [J]. Acta Materialia, 2003(51): 5775～5799
[6]徐河,刘静安,谢水生编著.镁合金制备与加工技术[M].北京:冶金工业出版社,2007
[7]袁晓光,刘彦学,王怡嵩,等.镁合金表面冷喷涂铝合金的界面扩散行为[J].焊接学报,2007,28(11):9-16
[8]陈振华.变形镁合金[M].北京:化学工业出版社,2005
[9]周海涛,马春江,曾小勤,等.变形镁合金材料的研究进展[J].材料导报,2003,17:16
[10]张士宏,许沂,王忠堂,等.镁合金成形加工技术[J].世界科技研究与发展,2001,23(6):18-21
[11]李小强.拉弯成形过程的数值模拟研究[D].西安:西北工业大学,2003
[12] Paulsen F., Welo T. Application of numerical simulation in the bending of aluminium-alloy profiles[J], Journal of Materials Processing Technology, 1996(58): 274-285
[13]杨玉英,董昀,赵立红.帽形型材绕弯件的曲率一致性[J].材料科学与工艺,2004,12(1):91-94
[14]臧鹏博.型材拉弯研究[D].西安:西北工业大学,2002
[15]陈毓勋.板材与型材弯曲回弹控制原理与方法[M].北京:国防工业出版社,1990
[16]周贤宾,刁可山,李晓星,等.闭截面型材的拉弯成形性[J].北京航空航天大学学报,2006,32(10):1168-1173
[17]金淼,周贤宾,李晓星,等.大尺寸封闭截面铝型材拉弯工艺研究[J].塑性工程学报,2003,10(6):46-49
[18]刁可山,周贤宾,金朝海,等.复杂截面型材力控制拉弯成形数值模拟分析[J].材料科学与工艺,2004,12(4):413-416
[19]金朝海,周贤宾.基于PS2F的铝型材拉弯回弹研究[J].塑性工程学报,2007,14(3):1-4
[20]王俊彪,于成龙,王永军,等.拉弯过程中预拉力对角型材零件回弹的影响规律[J].航空制造技术,2006(1):98-100
[21]张秉璋.横向压力影响拉弯零件回弹的研究[J].西北工业大学学报,1993,11(4):531-534
[22]钱志平,赵军.塑料包覆铝型材拉伸弯曲实验研究[J].塑性工程学报,2007,14(3):117-119
[23]钱志平,吕玫,高才良.中导轨拉弯成形截面畸变控制及模具设计[J].锻压技术,2001(3):47-48
[24]杨亚文.钛型材热拉弯蠕变成形电参数的计算[J].沈阳航空工业学院学报,2002,19(4):10-12
[25]张贺刚.型材转台式拉弯的力学分析与回弹分析[D].西安:西北工业大学,2004
[26]于成龙.型材转台式拉弯的力学分析与数值模拟[D].西安:西北工业大学,2005
[27]唐建阳,万敏.铝合金型材张力绕弯成形几何缺陷数值模拟分析[J].锻压技术,2005(1):29-32
[28]刘郁丽,卢彩红,赵刚要,等.间隙对薄壁矩形管绕弯成形截面畸变影响的研究[J].中国机械工程,2008,19(16):1972-1975
[29]李会来.方管弯曲模设计[J].模具工业,2002(4):32-35
[30]夏常平.薄壁矩形管弯曲的管壁变形分析与壁厚值计算[J].锻压技术,1995,20(6):26-30
[31]刘祖岩,刘刚,梁书锦. AZ31镁合金应力-应变关系的测定与四维描述[J].稀有金属材料与工程,2007,36(3):304-306
[32] EL-DOMIATY A. A., ELSHARKAWY A. A., Stretch-bending analysis ofU-section beams[J], International Journal of Machine Tools and Manufacture,1998, 38(1-2):75-95
[33] EL-Megharbel A., EL-Domiaty A., Shaker M., Springback and residual stresses after stretch bending of workhardening sheet metal[J], Journal of Materials Processing Technology, 1990(24):191-200
[34] Elsharkawy A. A., El-Domiaty A. A., Determination of stretch-bendability limits and springback for T-section beams[J], Journal of Materials Processing Technology, 2001(110):265-276
[35] EL-Domiaty A. A., Shabara M. A. N., AL-Ansary M. D., Determination of stretch-bendability of sheet-metals[J], International Journal of Machine Tools and Manufacture, 1996(36):635-650
[36] Clausen Arild H., Hopperstad Odd S., Langseth Magnus, Stretch bending of aluminum extrusions: Effect of tensile sequence[J], Journal of Engineering Mechanics, 1999(125):521-529
[37] Clausen A. H., Hopperstad O. S., Langseth M., Stretch bending of aluminium extrusions: Effect of geometry and alloy[J], Journal of Engineering Mechanics, 1999(125):392-400
[38] Clausen A. H., Tryland T., Remseth S. An investigation of material properties and geometrical dimensions of aluminium extrusions[J]. Materials and Design, 2001(22):267-275
[39] Clausen A. H., Hopperstad O. S., Langseth M., Sensitivity of model parameters in stretch bending of aluminium extrusions[C]. International Journal of Mechanical Sciences, 2001(43):427-453
[40] Paulsen F., Welo T. A design method prediction of dimensions of rectangular hollow sections formed in stretch bending[J]. Journal of Materials Processing Technology, 2002(128):8-66
[41] Paulsen F., Welo T. Cross-sectional deformations of rectangular hollow sections in bending: Part I - experiments[J]. International Journal of Mechanical Sciences, 2001(43):109-129
[42] Paulsen F., Welo T. Cross-sectional deformations of rectangular hollow sections in bending: Part II - analytical models[J]. International Journal of Mechanical Sciences, 2001(43):131-152
[43] Geiger M., Sprenger A., Controlled bending of Aluminum Extrusions[J], Annals ofthe CIRP, 1998(47): 197-202
[44] Corona E., Vaze S. P. Buckling of elastie Plastic square tubes under bending International Joumal of Mechanieal Seienees,1996,38(7):753～75
[45]左建民.液压与气压传动(第三版)[M].北京:机械工业出版社,2005
[46]张士宏,程明,王忠堂,等.有色金属板材若干温热加工成形技术的发展[J].锻压技术,2009,34(4):1-9
[47]姚启明,李双寿,李而立,等.客车镁合金管材电阻加热弯曲工艺[J].轻合金加工技术,2005,33(8):48-51
[48]张星,李保成,张治民.温变形对AZ31镁合金组织的影响[J].塑性工程学报,2004,11(3):52-54
[49]陈火红,杨剑,薛小香,等编著.新编Marc有限元实例教程[M].北京:机械工业出版社,2002
[50]陈火红,尹伟奇,薛小香. MSC.Marc二次开发指南[M].北京:科学出版社,2004
[51]张晓丽,李晓星,周贤宾,等.复杂截面铝合金型材拉弯成形有限元模拟[J].塑性工程学报,2004,11(4):44-47
[52]杨虎,刘琼荪,钟波.数理统计[M].北京:高等教育出版社,2004
[53]方开泰.均匀设计与均匀设计表[M].北京:科学出版社,1994
[54]宁俊生,范亚夫,彭秀峰.镁合金在大变形和高应变速率下塑性变形研究进展[J].材料工程,2007(9):67-73
[55]苏燕铃.孪生在镁合金塑性变形中的作用[D].南京:南京理工大学,2007
[56] Barnett M. R., Keshavara Z., Beer A. G., et al. Influence of grain size on the compressive deformation of wrought Mg-3Al-1Zn [J]. Acta Materialia, 2004,52 (17):5093-5103
[57]张津,章宗和,杨明波,等.镁合金及应用[M].北京:化学工业出版社,2004
[58]黄光杰,赵国丹. AZ31镁合金热变形规律的研究[J].重庆工学院学报,2006,20(2):60-64
[59]陈振华,杨春花,黄长清,等.镁合金塑性变形中孪生的研究[J].材料导报,2006,20(8):107-113
[60]严琦琦.挤压镁合金拉伸变形与断裂行为的研究[D].长沙:湖南大学,2006
[2]肖盼,刘天模,姜丹. AZ31镁合金的研究进展[J].重庆大学学报(自然科学版), 2006,29(11):81-84
[3]王里进. AZ31镁合金板材的塑性加工成形研究[D].重庆:重庆大学,2006
[4] Allwood J. M. A Structured Search for New Metal Forming Processes[C]. The 9th International Conference on Technology of Plasticity, 2008
[5] Williams J. C., Starke E. A., Jr. Progress in structural materials for aerospace systems [J]. Acta Materialia, 2003(51): 5775～5799
[6]徐河,刘静安,谢水生编著.镁合金制备与加工技术[M].北京:冶金工业出版社,2007
[7]袁晓光,刘彦学,王怡嵩,等.镁合金表面冷喷涂铝合金的界面扩散行为[J].焊接学报,2007,28(11):9-16
[8]陈振华.变形镁合金[M].北京:化学工业出版社,2005
[9]周海涛,马春江,曾小勤,等.变形镁合金材料的研究进展[J].材料导报,2003,17:16
[10]张士宏,许沂,王忠堂,等.镁合金成形加工技术[J].世界科技研究与发展,2001,23(6):18-21
[11]李小强.拉弯成形过程的数值模拟研究[D].西安:西北工业大学,2003
[12] Paulsen F., Welo T. Application of numerical simulation in the bending of aluminium-alloy profiles[J], Journal of Materials Processing Technology, 1996(58): 274-285
[13]杨玉英,董昀,赵立红.帽形型材绕弯件的曲率一致性[J].材料科学与工艺,2004,12(1):91-94
[14]臧鹏博.型材拉弯研究[D].西安:西北工业大学,2002
[15]陈毓勋.板材与型材弯曲回弹控制原理与方法[M].北京:国防工业出版社,1990
[16]周贤宾,刁可山,李晓星,等.闭截面型材的拉弯成形性[J].北京航空航天大学学报,2006,32(10):1168-1173
[17]金淼,周贤宾,李晓星,等.大尺寸封闭截面铝型材拉弯工艺研究[J].塑性工程学报,2003,10(6):46-49
[18]刁可山,周贤宾,金朝海,等.复杂截面型材力控制拉弯成形数值模拟分析[J].材料科学与工艺,2004,12(4):413-416
[19]金朝海,周贤宾.基于PS2F的铝型材拉弯回弹研究[J].塑性工程学报,2007,14(3):1-4
[20]王俊彪,于成龙,王永军,等.拉弯过程中预拉力对角型材零件回弹的影响规律[J].航空制造技术,2006(1):98-100
[21]张秉璋.横向压力影响拉弯零件回弹的研究[J].西北工业大学学报,1993,11(4):531-534
[22]钱志平,赵军.塑料包覆铝型材拉伸弯曲实验研究[J].塑性工程学报,2007,14(3):117-119
[23]钱志平,吕玫,高才良.中导轨拉弯成形截面畸变控制及模具设计[J].锻压技术,2001(3):47-48
[24]杨亚文.钛型材热拉弯蠕变成形电参数的计算[J].沈阳航空工业学院学报,2002,19(4):10-12
[25]张贺刚.型材转台式拉弯的力学分析与回弹分析[D].西安:西北工业大学,2004
[26]于成龙.型材转台式拉弯的力学分析与数值模拟[D].西安:西北工业大学,2005
[27]唐建阳,万敏.铝合金型材张力绕弯成形几何缺陷数值模拟分析[J].锻压技术,2005(1):29-32
[28]刘郁丽,卢彩红,赵刚要,等.间隙对薄壁矩形管绕弯成形截面畸变影响的研究[J].中国机械工程,2008,19(16):1972-1975
[29]李会来.方管弯曲模设计[J].模具工业,2002(4):32-35
[30]夏常平.薄壁矩形管弯曲的管壁变形分析与壁厚值计算[J].锻压技术,1995,20(6):26-30
[31]刘祖岩,刘刚,梁书锦. AZ31镁合金应力-应变关系的测定与四维描述[J].稀有金属材料与工程,2007,36(3):304-306
[32] EL-DOMIATY A. A., ELSHARKAWY A. A., Stretch-bending analysis ofU-section beams[J], International Journal of Machine Tools and Manufacture,1998, 38(1-2):75-95
[33] EL-Megharbel A., EL-Domiaty A., Shaker M., Springback and residual stresses after stretch bending of workhardening sheet metal[J], Journal of Materials Processing Technology, 1990(24):191-200
[34] Elsharkawy A. A., El-Domiaty A. A., Determination of stretch-bendability limits and springback for T-section beams[J], Journal of Materials Processing Technology, 2001(110):265-276
[35] EL-Domiaty A. A., Shabara M. A. N., AL-Ansary M. D., Determination of stretch-bendability of sheet-metals[J], International Journal of Machine Tools and Manufacture, 1996(36):635-650
[36] Clausen Arild H., Hopperstad Odd S., Langseth Magnus, Stretch bending of aluminum extrusions: Effect of tensile sequence[J], Journal of Engineering Mechanics, 1999(125):521-529
[37] Clausen A. H., Hopperstad O. S., Langseth M., Stretch bending of aluminium extrusions: Effect of geometry and alloy[J], Journal of Engineering Mechanics, 1999(125):392-400
[38] Clausen A. H., Tryland T., Remseth S. An investigation of material properties and geometrical dimensions of aluminium extrusions[J]. Materials and Design, 2001(22):267-275
[39] Clausen A. H., Hopperstad O. S., Langseth M., Sensitivity of model parameters in stretch bending of aluminium extrusions[C]. International Journal of Mechanical Sciences, 2001(43):427-453
[40] Paulsen F., Welo T. A design method prediction of dimensions of rectangular hollow sections formed in stretch bending[J]. Journal of Materials Processing Technology, 2002(128):8-66
[41] Paulsen F., Welo T. Cross-sectional deformations of rectangular hollow sections in bending: Part I - experiments[J]. International Journal of Mechanical Sciences, 2001(43):109-129
[42] Paulsen F., Welo T. Cross-sectional deformations of rectangular hollow sections in bending: Part II - analytical models[J]. International Journal of Mechanical Sciences, 2001(43):131-152
[43] Geiger M., Sprenger A., Controlled bending of Aluminum Extrusions[J], Annals ofthe CIRP, 1998(47): 197-202
[44] Corona E., Vaze S. P. Buckling of elastie Plastic square tubes under bending International Joumal of Mechanieal Seienees,1996,38(7):753～75
[45]左建民.液压与气压传动(第三版)[M].北京:机械工业出版社,2005
[46]张士宏,程明,王忠堂,等.有色金属板材若干温热加工成形技术的发展[J].锻压技术,2009,34(4):1-9
[47]姚启明,李双寿,李而立,等.客车镁合金管材电阻加热弯曲工艺[J].轻合金加工技术,2005,33(8):48-51
[48]张星,李保成,张治民.温变形对AZ31镁合金组织的影响[J].塑性工程学报,2004,11(3):52-54
[49]陈火红,杨剑,薛小香,等编著.新编Marc有限元实例教程[M].北京:机械工业出版社,2002
[50]陈火红,尹伟奇,薛小香. MSC.Marc二次开发指南[M].北京:科学出版社,2004
[51]张晓丽,李晓星,周贤宾,等.复杂截面铝合金型材拉弯成形有限元模拟[J].塑性工程学报,2004,11(4):44-47
[52]杨虎,刘琼荪,钟波.数理统计[M].北京:高等教育出版社,2004
[53]方开泰.均匀设计与均匀设计表[M].北京:科学出版社,1994
[54]宁俊生,范亚夫,彭秀峰.镁合金在大变形和高应变速率下塑性变形研究进展[J].材料工程,2007(9):67-73
[55]苏燕铃.孪生在镁合金塑性变形中的作用[D].南京:南京理工大学,2007
[56] Barnett M. R., Keshavara Z., Beer A. G., et al. Influence of grain size on the compressive deformation of wrought Mg-3Al-1Zn [J]. Acta Materialia, 2004,52 (17):5093-5103
[57]张津,章宗和,杨明波,等.镁合金及应用[M].北京:化学工业出版社,2004
[58]黄光杰,赵国丹. AZ31镁合金热变形规律的研究[J].重庆工学院学报,2006,20(2):60-64
[59]陈振华,杨春花,黄长清,等.镁合金塑性变形中孪生的研究[J].材料导报,2006,20(8):107-113
[60]严琦琦.挤压镁合金拉伸变形与断裂行为的研究[D].长沙:湖南大学,2006