螺纹冷滚压模拟及实验研究
摘要
螺纹滚压是一种无切削加工方法,近年来螺纹冷滚压工艺及设备因其低耗、高效、高强度和高精度等优点,在生产中得到了广泛的应用。但是目前国内外在螺纹冷滚压精密成形的工艺方面的研究较少。因此对螺纹冷滚压进行研究,有助于促进这种无切削新技术的推广应用,具有重要的理论意义和实用价值。
本文对螺纹冷滚压过程及原理进行了分析,将螺纹的滚压过程分为了四个阶段,并对四个阶段的成形过程进行了系统的分析。
用DEFORM软件进行有限元数值模拟,得到了冷滚压加工过程中工件内部的应力场、应变场、速度场以及工件的形状变化等信息。
在实验方面从金相组织、硬度分布及硬化层、等几个方面进行了对比分析。通过数值模拟得出了冷滚压螺纹在滚压过程中的受力情况,并验证了螺纹冷滚压理论分析的正确。
通过金相组织实验可知冷滚压螺纹的表层组织被压碎,晶界变的模糊不清,而切削螺纹的金属被切断,金属组织未发生明显变化。冷滚压螺纹表面硬度高于切削螺纹面的硬度,冷滚压后的螺纹其硬度值可达330HV,而切削螺纹的硬度值基本没有发生变化,其硬度值为220HV。滚压螺纹的金属组织呈现连续分布的条形纤维组织,而切削螺纹的纤维组织被切断。调质处理的坯料在冷滚压加工后工件的组织性能及表面强化程度均优于未经调质处理的坯料滚压成形的工件。
本课题为进一步研究螺纹冷滚压工艺提供了理论依据,并能够指导螺纹冷滚压的生产,具有理论价值和现实意义。
In recent years, the technology cold rolling of thread technology was rapidly developed due to its high efficiency, low cost and perfect properties of its production. Few studies were carried out on the cold-rolling technological theory and the mechanical analysis of the precise forming both at home and abroad. Therefore, the research on the cold rolling of thread has important theoretical and practical value. It can promote the application of this non-cutting methord to be more popular.
In this paper, the cold thread rolling process and theory were analyzed. The rolling process was divided into four stages according to the amount of feed of the thread rolling dies.
The numerical simulations on the rolling process of solid parts were carried out with DEFORM software. The stress field, strain field, velocity field in the workpiece were got.
In the experiments the microstructure, hardness and hardened layer, and several other areas were compared. The force of cold rolling thread was obtained by numerical simulation.And the theory of cold rolling thread was verified.
Through the analysis and the comparation of the microstructure, hardness and hardened layer and residual stress, we conclude that: The microstructure of Cold rolled thread was crushed, grain boundaries become blurred, and the cutting threads were cut off, metal structure did not change significantly. the surface hardness of cold-rolling thread was better than cutting thread. Hardness of cold-rolling thread which was treated after heat treatment can reach 330HV, in contrast before heat treatment can only reach 220HV. The hardened layer of the cold-rolled thread have a certain depth in normal direction, otherwise, the hardness of the thread cutting have no diversification; cold rolled thread surface area have a continuous fibrous structure, and the microstructure was refined. The structure property and the suface hardness of thread which is rolled after heat treatment is better than cold rolled before heatment.
The conclusion provides the theoretical basis for the further research of the cold rolling technology and practical operation. It has a theoretical significance and practical value.
本文对螺纹冷滚压过程及原理进行了分析,将螺纹的滚压过程分为了四个阶段,并对四个阶段的成形过程进行了系统的分析。
用DEFORM软件进行有限元数值模拟,得到了冷滚压加工过程中工件内部的应力场、应变场、速度场以及工件的形状变化等信息。
在实验方面从金相组织、硬度分布及硬化层、等几个方面进行了对比分析。通过数值模拟得出了冷滚压螺纹在滚压过程中的受力情况,并验证了螺纹冷滚压理论分析的正确。
通过金相组织实验可知冷滚压螺纹的表层组织被压碎,晶界变的模糊不清,而切削螺纹的金属被切断,金属组织未发生明显变化。冷滚压螺纹表面硬度高于切削螺纹面的硬度,冷滚压后的螺纹其硬度值可达330HV,而切削螺纹的硬度值基本没有发生变化,其硬度值为220HV。滚压螺纹的金属组织呈现连续分布的条形纤维组织,而切削螺纹的纤维组织被切断。调质处理的坯料在冷滚压加工后工件的组织性能及表面强化程度均优于未经调质处理的坯料滚压成形的工件。
本课题为进一步研究螺纹冷滚压工艺提供了理论依据,并能够指导螺纹冷滚压的生产,具有理论价值和现实意义。
In recent years, the technology cold rolling of thread technology was rapidly developed due to its high efficiency, low cost and perfect properties of its production. Few studies were carried out on the cold-rolling technological theory and the mechanical analysis of the precise forming both at home and abroad. Therefore, the research on the cold rolling of thread has important theoretical and practical value. It can promote the application of this non-cutting methord to be more popular.
In this paper, the cold thread rolling process and theory were analyzed. The rolling process was divided into four stages according to the amount of feed of the thread rolling dies.
The numerical simulations on the rolling process of solid parts were carried out with DEFORM software. The stress field, strain field, velocity field in the workpiece were got.
In the experiments the microstructure, hardness and hardened layer, and several other areas were compared. The force of cold rolling thread was obtained by numerical simulation.And the theory of cold rolling thread was verified.
Through the analysis and the comparation of the microstructure, hardness and hardened layer and residual stress, we conclude that: The microstructure of Cold rolled thread was crushed, grain boundaries become blurred, and the cutting threads were cut off, metal structure did not change significantly. the surface hardness of cold-rolling thread was better than cutting thread. Hardness of cold-rolling thread which was treated after heat treatment can reach 330HV, in contrast before heat treatment can only reach 220HV. The hardened layer of the cold-rolled thread have a certain depth in normal direction, otherwise, the hardness of the thread cutting have no diversification; cold rolled thread surface area have a continuous fibrous structure, and the microstructure was refined. The structure property and the suface hardness of thread which is rolled after heat treatment is better than cold rolled before heatment.
The conclusion provides the theoretical basis for the further research of the cold rolling technology and practical operation. It has a theoretical significance and practical value.
引文
[1]王秀伦.螺纹冷滚压加工技术.北京:中国铁道出版社, 1990
[2]崔长华.螺纹的滚压加工.北京:机械工业出版社, 1978
[3] Joseph P. Domblesky,Ph.D Computer Simulation of Thread Polling Processes. Fastener Technology International, 1999.8
[4]吕琳,刘利,渐开线花键的冷挤压成形试验研究,重庆工商大学学报,2004年,第2l卷第4期,第403-405页。
[5] thread rolling. DIALOG,On Disc Books, ASM HANDBook machining. Materials Park,OH:ASM International, 2001(vol.16) P1~20
[6] Z.Pater, A.Gontarz, W.Weron~ ski. New method of thread rolling. Journal of Materials Processing Technology, 2004.04.154(Vol.153~154) P722~728。
[7]计志孝,张荣珍,陈景涛,刘文田.螺纹加工新工艺.北京:兵器工业出版社, 1990
[8] Round up: thread rolling machine Fasterner technology international, 2001.06 P55~60
[9]崔凤奎,李言,周彦伟等,渐开线花键轴冷滚轧工艺试验,农业机械学报,2006.12,第37卷第12期,第189-192页。
[10]N.M.Agaev,A.Yu.Alekperov,S.B.Gatamov,Technology of producing equipment 1992.07 P540-543
[11]郑全刚,圆柱直齿小模数渐开线花键冷滚轧成形技术,汽车工艺与材料,1997年,第7期,第16-18页。
[12]俞汉清,陈金德.金属塑性成形原理.北京:机械工业出版社, 1999.3。
[13]李景新,在滚丝机上加工渐开线花键,生产技术,2003年,第2期,第29-30页。
[14]胡正寰,张康生,王宝雨,张巍.楔横轧理论与应用.北京:冶金工业出版社, 1995.6
[15] R. Matsunaga, T. Ozaki, T. Takemasu, et al. Optimum design of outer tools usingspline rolling simulation model-spline rolling of deep drawn cupsⅢ.《塑性加工》, 1998, Vol.39, no.446, pp.22～26.
[16] V.V.Klepikov, A.N.Bodrov, Precise shaping of splined shafts in automobile manufacturing, Russian Engineering Research, 2003, vol.23, pp.37～40.
[17]马钦.再谈滚压外螺纹螺坯直径的计算.紧固件技术, 2000.2 P11~13。
[18]赵俊杰,马振海,胡正寰.斜轧螺纹过程的数值模拟.钢铁研究学报, 2002.2
[19] Jarvis L. Dotson, Charles R. Henrey, Jay Westra, Joseph P. Domblesky. Experimentalinvestigation of external thread rolling. The wine Association Internation, Inc. Wire &Cable Technical Symposium (WCTS) and 71st Annual convention, May,2001,Atlanta,Georgia USA, P90~95
[20] J. P. Domblesky, F. Feng. Two-dimensional and three-dimensional finite element models of external thread rolling. Proceedings of the Institution of Mechanical Engineers, part B. 2002,vol.216, No.134 , P507~509
[21]田也,螺旋渐开线花键冷滚轧成形规律研究,[学位论文],湖北省,武汉理工大学,2008年。
[22] Dr.-ing Thomas Herlan, cross rolling, forging technology, 2002, No.2, pp.17-18.
[23] Joseph P. Domblesky Feng Feng, Finite element modeling of external thread rolling, wire journal international, 2001, vol.9, pp.110-116.
[24] Z.Pater, A.Gontarz, W.Weronski, New method of thread rolling, Journal of Materials Processing Technology, 2004, Vol.(153～154), pp.722-728.
[25] Li Zhiqiang, Lu Yuqiu, Lu Sgouli, Modelling and simulation of deformation zone in cross rolling mill. Steel Research, 1991, vol.68, No.5, pp.220-223.
[26] Z.H.Hu, X.H.Xu, D.J.Sha, Skew Rolling and Cross Wedge Rolling -Principles, Processes and Machines, 1985, P367-400.
[27]李冰,原思聪.有限单元法在外螺纹斜轧机轧辊设计计算中应用.重型机械, 2001,No.2 P48~51。
[28]李晓滨.国外搓丝工艺控制技术.航空标准化与质量, 1999.01 P41~42
[29]李晓滨.螺纹搓丝技术研讨会小结.航空标准化与质量, 1998.05 P18~22
[30] D.D.Wang, A.K.Tieu, C.Lu, Giovanni D’Alessio. W.Y.D.Yuen. Modeling and Optincization of threading for shape contl in tandem cold rolling. Journal of Materials Processing Technology. Vol.140/1-3, P562~568
[31]刘鸿文.材料力学.北京:高等教育出版社, 1979。
[32]张伯良.螺纹的挤压加工.内燃机, 1998.1 P10-13
[33] S. V. S. Rithalia, J. Tinker, Continuous Flush Devices for Pressure Monitoring, Intensive Care Medicine, 1983, vol.9, pp.295-298.
[34] Steven P. Underation, State-of-the-Art Process Control for Thread Rolling. Fastener technology international, 1999, vol.22, No.12, pp.60-62.
[35]丁开录,万雨樵.谈谈航天螺纹的滚压.航空标准化与质量, 1996.5 P6-10
[36] Chi-Hang, Chen Shui-To, Wang Rong-Shean Lee. 3-D Finite Element Simulation for Flat-Die Thread Rolling of Stainless Steel. Journal of the Chinese Society of Mechanical Engineers. Series C. 2005,Vol.26 ,P616-622
[37] Yair Wiesenfeld. Trends and developments in thread rolling machines and tooling. Wire Industry,2000.08,P697-700
[38] C.R.Gagg. Premature failure of thread rolling dies: material selection, hardness criteria and case studies. Engineering Failure Analysis,2001.V8,No1
[39]Hsin-Yu Cheng,Yung-Chou. Kao. Study on an Integrated Process for Screw Rolling Die Plate Development. Journal of the Chinese Society of Mechanical Engineers. Vol26, No5, P571-577(2005)
[40] Thomas Kopka Anton Schwer. Thread rolling on the night shift. Wire Industry,2003,Vol.70,P136-139
[41] S.Ifergane, N.Eliaz, N.stern. The effect of manufacturing processes on the fatigue lifetime of aeronautical bolts. Engineering Failure Analysis.2001.08.P226-235.
[42]张优云,陈花玲,张小栋,现代机械测试技术,北京,科学出版社,2005年。
[42]王仲仁.塑性加工力学基础.北京:国防工业出版社, 1989.10
[43]张有颐,测量技术,北京,计量出版社,1986年。
[44] Giovanni Volpe, Dmitri Petrov, Torque Detection using Brownian Fluctuations, The American Physical Society, 2006, No.24, P1-4.
[45] R. Matsunaga, T. Ozaki, T. Takemasu, R. Kamashita,H. Tsukamoto, A.Tanaka. Optimum design of outer tools using spline rolling simulation model-spline rolling of deep drawn cupsⅢ.《塑性と加工》, 1998,Vol.39,no.446 P22~26
[46] Patrick Riley. New Generation of Process Monitors. Fastener technology international , 1999, vol.22, No.8 ,49~50
[2]崔长华.螺纹的滚压加工.北京:机械工业出版社, 1978
[3] Joseph P. Domblesky,Ph.D Computer Simulation of Thread Polling Processes. Fastener Technology International, 1999.8
[4]吕琳,刘利,渐开线花键的冷挤压成形试验研究,重庆工商大学学报,2004年,第2l卷第4期,第403-405页。
[5] thread rolling. DIALOG,On Disc Books, ASM HANDBook machining. Materials Park,OH:ASM International, 2001(vol.16) P1~20
[6] Z.Pater, A.Gontarz, W.Weron~ ski. New method of thread rolling. Journal of Materials Processing Technology, 2004.04.154(Vol.153~154) P722~728。
[7]计志孝,张荣珍,陈景涛,刘文田.螺纹加工新工艺.北京:兵器工业出版社, 1990
[8] Round up: thread rolling machine Fasterner technology international, 2001.06 P55~60
[9]崔凤奎,李言,周彦伟等,渐开线花键轴冷滚轧工艺试验,农业机械学报,2006.12,第37卷第12期,第189-192页。
[10]N.M.Agaev,A.Yu.Alekperov,S.B.Gatamov,Technology of producing equipment 1992.07 P540-543
[11]郑全刚,圆柱直齿小模数渐开线花键冷滚轧成形技术,汽车工艺与材料,1997年,第7期,第16-18页。
[12]俞汉清,陈金德.金属塑性成形原理.北京:机械工业出版社, 1999.3。
[13]李景新,在滚丝机上加工渐开线花键,生产技术,2003年,第2期,第29-30页。
[14]胡正寰,张康生,王宝雨,张巍.楔横轧理论与应用.北京:冶金工业出版社, 1995.6
[15] R. Matsunaga, T. Ozaki, T. Takemasu, et al. Optimum design of outer tools usingspline rolling simulation model-spline rolling of deep drawn cupsⅢ.《塑性加工》, 1998, Vol.39, no.446, pp.22～26.
[16] V.V.Klepikov, A.N.Bodrov, Precise shaping of splined shafts in automobile manufacturing, Russian Engineering Research, 2003, vol.23, pp.37～40.
[17]马钦.再谈滚压外螺纹螺坯直径的计算.紧固件技术, 2000.2 P11~13。
[18]赵俊杰,马振海,胡正寰.斜轧螺纹过程的数值模拟.钢铁研究学报, 2002.2
[19] Jarvis L. Dotson, Charles R. Henrey, Jay Westra, Joseph P. Domblesky. Experimentalinvestigation of external thread rolling. The wine Association Internation, Inc. Wire &Cable Technical Symposium (WCTS) and 71st Annual convention, May,2001,Atlanta,Georgia USA, P90~95
[20] J. P. Domblesky, F. Feng. Two-dimensional and three-dimensional finite element models of external thread rolling. Proceedings of the Institution of Mechanical Engineers, part B. 2002,vol.216, No.134 , P507~509
[21]田也,螺旋渐开线花键冷滚轧成形规律研究,[学位论文],湖北省,武汉理工大学,2008年。
[22] Dr.-ing Thomas Herlan, cross rolling, forging technology, 2002, No.2, pp.17-18.
[23] Joseph P. Domblesky Feng Feng, Finite element modeling of external thread rolling, wire journal international, 2001, vol.9, pp.110-116.
[24] Z.Pater, A.Gontarz, W.Weronski, New method of thread rolling, Journal of Materials Processing Technology, 2004, Vol.(153～154), pp.722-728.
[25] Li Zhiqiang, Lu Yuqiu, Lu Sgouli, Modelling and simulation of deformation zone in cross rolling mill. Steel Research, 1991, vol.68, No.5, pp.220-223.
[26] Z.H.Hu, X.H.Xu, D.J.Sha, Skew Rolling and Cross Wedge Rolling -Principles, Processes and Machines, 1985, P367-400.
[27]李冰,原思聪.有限单元法在外螺纹斜轧机轧辊设计计算中应用.重型机械, 2001,No.2 P48~51。
[28]李晓滨.国外搓丝工艺控制技术.航空标准化与质量, 1999.01 P41~42
[29]李晓滨.螺纹搓丝技术研讨会小结.航空标准化与质量, 1998.05 P18~22
[30] D.D.Wang, A.K.Tieu, C.Lu, Giovanni D’Alessio. W.Y.D.Yuen. Modeling and Optincization of threading for shape contl in tandem cold rolling. Journal of Materials Processing Technology. Vol.140/1-3, P562~568
[31]刘鸿文.材料力学.北京:高等教育出版社, 1979。
[32]张伯良.螺纹的挤压加工.内燃机, 1998.1 P10-13
[33] S. V. S. Rithalia, J. Tinker, Continuous Flush Devices for Pressure Monitoring, Intensive Care Medicine, 1983, vol.9, pp.295-298.
[34] Steven P. Underation, State-of-the-Art Process Control for Thread Rolling. Fastener technology international, 1999, vol.22, No.12, pp.60-62.
[35]丁开录,万雨樵.谈谈航天螺纹的滚压.航空标准化与质量, 1996.5 P6-10
[36] Chi-Hang, Chen Shui-To, Wang Rong-Shean Lee. 3-D Finite Element Simulation for Flat-Die Thread Rolling of Stainless Steel. Journal of the Chinese Society of Mechanical Engineers. Series C. 2005,Vol.26 ,P616-622
[37] Yair Wiesenfeld. Trends and developments in thread rolling machines and tooling. Wire Industry,2000.08,P697-700
[38] C.R.Gagg. Premature failure of thread rolling dies: material selection, hardness criteria and case studies. Engineering Failure Analysis,2001.V8,No1
[39]Hsin-Yu Cheng,Yung-Chou. Kao. Study on an Integrated Process for Screw Rolling Die Plate Development. Journal of the Chinese Society of Mechanical Engineers. Vol26, No5, P571-577(2005)
[40] Thomas Kopka Anton Schwer. Thread rolling on the night shift. Wire Industry,2003,Vol.70,P136-139
[41] S.Ifergane, N.Eliaz, N.stern. The effect of manufacturing processes on the fatigue lifetime of aeronautical bolts. Engineering Failure Analysis.2001.08.P226-235.
[42]张优云,陈花玲,张小栋,现代机械测试技术,北京,科学出版社,2005年。
[42]王仲仁.塑性加工力学基础.北京:国防工业出版社, 1989.10
[43]张有颐,测量技术,北京,计量出版社,1986年。
[44] Giovanni Volpe, Dmitri Petrov, Torque Detection using Brownian Fluctuations, The American Physical Society, 2006, No.24, P1-4.
[45] R. Matsunaga, T. Ozaki, T. Takemasu, R. Kamashita,H. Tsukamoto, A.Tanaka. Optimum design of outer tools using spline rolling simulation model-spline rolling of deep drawn cupsⅢ.《塑性と加工》, 1998,Vol.39,no.446 P22~26
[46] Patrick Riley. New Generation of Process Monitors. Fastener technology international , 1999, vol.22, No.8 ,49~50