带轮旋压成形新工艺的有限元模拟研究
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摘要
旋压成形可旋制整体无缝回转体零件,具有变形条件好、产品性能优、尺寸公差小、材料利用率高、产品类别广泛等优点,广泛应用于航空、船舶、军工、民用等金属精密加工技术领域。本文结合实际生产过程中遇到的问题,研究了空调离合器带轮的铲旋旋压成形和宽平皮带轮的旋压成形,基于有限元模拟技术,实现了产品工艺的改进和工艺参数的优化,有效地提高了产品质量。
空调离合器带轮是带法兰盘的双筒形零件,是汽车空调离合器的重要零件。若采用传统的锻造毛坯经机械加工和焊接方法来生产,不但工序复杂,工时多,而且材料利用率低,成本高。一种新的旋压方法,直接从平板毛坯上旋制出双筒形的铲旋旋压技术获得成功应用。本文首先采用DEFORM软件建立了符合实际生产的铲旋旋压有限元模型,并对模拟结果进行了试验验证；再通过正交试验,以降低旋轮所受成形载荷为目标,对工艺参数进行优化；最后利用优化结果进行模拟,旋轮所受成形载荷明显下降,得到了满意的效果。研究表明,在保证工件成形质量和生产率的前提下,较大的旋轮转速和进给速度、合理的旋轮圆角半径和旋轮直径有利于降低成形载荷,保护旋轮。
平带轮运转平稳,传动可靠,一般用于高速传动中。为了防止在启动和运转中皮带打滑脱出,常常需加工轮缘凸度。本文研究的宽平皮带轮,不需要加工轮缘凸度,只是用两端的坡度来卡住皮带,保证传动运行。在宽平皮带轮旋压成形过程中,采用劈开式预旋轮代替挤压式预旋轮的新工艺,减小成形载荷,有利于带轮成形并延长了旋轮使用寿命。为了验证新工艺的可行性,分别对宽平皮带轮旋压成形两种工艺进行有限元模拟,提取应力场、应变场、行程与载荷曲线等模拟结果进行对比,进一步证明了新工艺的优点。分析了工艺参数对宽平皮带轮旋压成形的影响,为生产调试提供参考。研究表明,采用宽平皮带轮成形新工艺,降低了成形载荷,提高了生产效率。
空调离合器带轮铲旋旋压和宽平皮带轮特种旋压两种旋压工艺方法的研究结论对实际生产都有一定的指导作用。
Spinning easily manufactures the product of whole seamless hollow rotary body. It has many advantages, including good deformation conditions, excellent product performance, precise dimensional tolerances, high material utilization ratio, great product categories and so on. It has been widely application in aviation, shipping, military, civil and other metal precision forming technology departments. This paper combined with the actual production process problems. Air-conditioning clutch pulley and wide flat belt pulley's spinning are regarded as the main research contents. Based on the FEM simulation technology to modification product processes, optimize process parameters and effectively improve the product quality.
Air-conditioning clutch pulley is a double-barrel-shaped part with a flange, is an important part of air-conditioning clutches. If using the traditional forging blank by machining and welding to produce, it'll not only cost complex process and more working hours, but also bring low material utilization and high cost. After repeated trials the researchers developed a new type of spinning method:shovel spinning, directly from the flat blank for a double-barrel-shaped. First of all, using DEFORM software established the shovel spinning FEM model and verified simulation results through testing. Then, the value of forming load as the target use orthogonal test to optimize the process parameters. Finally, simulating the results of optimization, the value of forming load decrease and get satisfactory results. Study shows that in ensuring the quality and productivity, larger speed and feed rate, reasonable fillet radius and roller diameter to reduce the value of forming load and to protect the roller.
Flat pulley is generally used for high-speed transmission because of stable operation and reliable transmission. In order to prevent belt slippage in start-up and operation, usually need to process rim convexity. In this paper, a wide flat pulley, without processing rim convexity, but stuck with the belt at both ends of the slope to ensure the drive is running. In the process of the pulley's spinning forming, the use of split-type pre-spinning wheel instead of squeeze-type pre-spinning wheel, reducing the forming load and is conducive to forming pulley and extends service life of the spinning wheel. To verify the feasibility of new technology, respectively simulated two different spinning processes, achieved the stress field, the strain filed, the load curve with stroke and so on. These simulation results were compared, further to demonstrate the advantages of new technology. Analysis of the process parameters on the wide flat pulley spinning, provide a reference for the produce debugging. The study shows that using the new technology can reduce the forming load and improve production efficiency.
Shovel spinning of air-conditioning clutch pulley and flat belt pulley spinning, research findings of these two kinds of spinning technology have a certain amount of guidance on actual production.
空调离合器带轮是带法兰盘的双筒形零件,是汽车空调离合器的重要零件。若采用传统的锻造毛坯经机械加工和焊接方法来生产,不但工序复杂,工时多,而且材料利用率低,成本高。一种新的旋压方法,直接从平板毛坯上旋制出双筒形的铲旋旋压技术获得成功应用。本文首先采用DEFORM软件建立了符合实际生产的铲旋旋压有限元模型,并对模拟结果进行了试验验证；再通过正交试验,以降低旋轮所受成形载荷为目标,对工艺参数进行优化；最后利用优化结果进行模拟,旋轮所受成形载荷明显下降,得到了满意的效果。研究表明,在保证工件成形质量和生产率的前提下,较大的旋轮转速和进给速度、合理的旋轮圆角半径和旋轮直径有利于降低成形载荷,保护旋轮。
平带轮运转平稳,传动可靠,一般用于高速传动中。为了防止在启动和运转中皮带打滑脱出,常常需加工轮缘凸度。本文研究的宽平皮带轮,不需要加工轮缘凸度,只是用两端的坡度来卡住皮带,保证传动运行。在宽平皮带轮旋压成形过程中,采用劈开式预旋轮代替挤压式预旋轮的新工艺,减小成形载荷,有利于带轮成形并延长了旋轮使用寿命。为了验证新工艺的可行性,分别对宽平皮带轮旋压成形两种工艺进行有限元模拟,提取应力场、应变场、行程与载荷曲线等模拟结果进行对比,进一步证明了新工艺的优点。分析了工艺参数对宽平皮带轮旋压成形的影响,为生产调试提供参考。研究表明,采用宽平皮带轮成形新工艺,降低了成形载荷,提高了生产效率。
空调离合器带轮铲旋旋压和宽平皮带轮特种旋压两种旋压工艺方法的研究结论对实际生产都有一定的指导作用。
Spinning easily manufactures the product of whole seamless hollow rotary body. It has many advantages, including good deformation conditions, excellent product performance, precise dimensional tolerances, high material utilization ratio, great product categories and so on. It has been widely application in aviation, shipping, military, civil and other metal precision forming technology departments. This paper combined with the actual production process problems. Air-conditioning clutch pulley and wide flat belt pulley's spinning are regarded as the main research contents. Based on the FEM simulation technology to modification product processes, optimize process parameters and effectively improve the product quality.
Air-conditioning clutch pulley is a double-barrel-shaped part with a flange, is an important part of air-conditioning clutches. If using the traditional forging blank by machining and welding to produce, it'll not only cost complex process and more working hours, but also bring low material utilization and high cost. After repeated trials the researchers developed a new type of spinning method:shovel spinning, directly from the flat blank for a double-barrel-shaped. First of all, using DEFORM software established the shovel spinning FEM model and verified simulation results through testing. Then, the value of forming load as the target use orthogonal test to optimize the process parameters. Finally, simulating the results of optimization, the value of forming load decrease and get satisfactory results. Study shows that in ensuring the quality and productivity, larger speed and feed rate, reasonable fillet radius and roller diameter to reduce the value of forming load and to protect the roller.
Flat pulley is generally used for high-speed transmission because of stable operation and reliable transmission. In order to prevent belt slippage in start-up and operation, usually need to process rim convexity. In this paper, a wide flat pulley, without processing rim convexity, but stuck with the belt at both ends of the slope to ensure the drive is running. In the process of the pulley's spinning forming, the use of split-type pre-spinning wheel instead of squeeze-type pre-spinning wheel, reducing the forming load and is conducive to forming pulley and extends service life of the spinning wheel. To verify the feasibility of new technology, respectively simulated two different spinning processes, achieved the stress field, the strain filed, the load curve with stroke and so on. These simulation results were compared, further to demonstrate the advantages of new technology. Analysis of the process parameters on the wide flat pulley spinning, provide a reference for the produce debugging. The study shows that using the new technology can reduce the forming load and improve production efficiency.
Shovel spinning of air-conditioning clutch pulley and flat belt pulley spinning, research findings of these two kinds of spinning technology have a certain amount of guidance on actual production.
引文
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[2]董湘怀,黄树槐,李志刚等.塑性加工技术的发展趋势.中国机械工程,2000,11(9)：1074-1077
[3]李德群.塑性加工技术发展状况及趋势.航空制造技术,2000(3)：27-30
[4]汪大年.金属塑性成形原理.第一版.高等教育出版社,1988：1-245
[5]日本塑性加工学会.旋压成形技术.陈敬之译.北京：机械工业出版社,1988
[6]Atsushi BAB A. Current status and view of high precision spinning. JSTP, 1988(29):13-20
[7]徐恒秋,樊桂森等.旋压设备及工艺技术的应用与发展.新技术新工艺,2007(2)：5-8
[8]陈芳雷,张治民等.旋压技术在皮带轮中的应用.工艺与检测,2007
[9]王忠清.钣制旋压皮带轮在汽车行业的发展及应用.汽车与配件,1998(25)：18-19
[10]陈适先,贾文铎等.强力旋压工艺与设备.国防工业出版社,1988
[11]王成和,刘克璋等.旋压技术.机械工业出版社,1986
[12]赵云豪,李彦利.旋压技术与应用.北京：机械工业出版社,2007
[13]党民,叶喜山等.国内旋压技术的现状和发展.机械工人：热加工,2003,(4)：44-45
[14]D. Pollitt. Automatic spinning-a revolution in the making. Sheet Metal Ind, 1981(7):515-522
[15]D. Pollitt. Automatic spinning-a production technique. Sheet Metal Ind, 1982(6):518-526
[16]Matsunok. Recent research and development in metal forming in Japan. Journal of Materials Processing Technology,1997(6):1-3
[17]夏琴香.三维非轴对称零件旋压成型工艺与设备.新技术新工艺,2003,(12)： 33-35
[18]张顺福,孙存福.国产旋压设备的发展和应用.金属成型工艺,2003,21(1)：1-4
[19]肖作义.筒形件强力旋压新技术——浮动芯模法.锻压技术,1999,(5)：34-35
[20]冯万林,夏琴香等.选压力的测试方法及试验研究.特种成形,2005,(4)： 88-92
[21]卫原平,王轶为.工艺参数对筒形件强力旋压过程的影响.模具技术,2000,(4)：12-18
[22]赵云豪,张顺福.国内旋压技术发展的回顾与展望.第七届全国旋压学术年会论文集,1999：419-425
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