四边圆弧形横截面空心零件旋压成形数值模拟及试验研究
|
摘要
现代旋压技术具有高效率、省材料、模具简单、环保、经济效益高等优点,因而广泛应用于金属成形领域。近年来,一些非圆截面空心零件采用旋压技术进行加工,突破了传统旋压技术的范畴——旋压只能加工轴对称回转体的空心零件。
本课题来源于国家自然科学基金项目(50775076)“非圆截面空心零件旋压成形方法及变形机理研究”。论文主要以四边圆弧形横截面空心零件为研究对象,对其旋压成形的数值模拟及试验进行研究,为后续多种非圆横截面空心零件旋压成形方法以及旋压成形机理的探索奠定基础。主要内容如下:
1、分析四边圆弧形横截面空心零件的旋压成形工艺,结合三维软件Pro/e以及运动仿真软件ADAMS获得旋轮运动轨迹,运用MSC.MARC软件建立有限元数值模型;
2、对有限元数值模拟结果进行分析,主要分析的内容:应力应变分布规律、主要工艺参数对工件成形质量的影响;
3、比较三边圆弧形和四边圆弧形横截面空心零件旋压成形的应力应变分布规律,以及主要工艺参数对两者成形质量影响规律的差异性;
4、结合HGPX-WSM机床结构,并且在三边圆弧形横截面空心零件旋压靠模型面的设计方法的基础上,分析并且比较解析法和离散数据点的B样条曲线拟合法设计的靠模型面。首先采用这两种方法分别设计出靠模型面,然后运用ADAMS软件分析靠模型面的误差大小以及误差分布,最终选择离散数据点的B样条曲线拟合法;
5、以数值模拟分析结果为指导,使用HGPX-WSM型多功能卧式数控旋压机,进行四边圆弧形横截面空心零件单道次拉深旋压工艺试验。研究旋轮轴向进给比、主轴转速等工艺参数对旋压件成形质量的影响规律。同时将试验结果和模拟结果进行比较,验证有限元模型的合理性。
Spinning is widely used in the field of metal forming, not only with the advantages of high forming precision, low cost and high quality, but also it can bring multiple benefits such as environmental protection, economy and so on. In recent years, some of the hollow parts with non-circular section can be produced by spinning, which breaks through the limit of spinning only producing hollow parts with circular section.
This paper is financially supported by the project“Research on spinning forming method and deformation mechanism of the hollow part with non-circular section”(50775076), which is a National Natural Scientific Fund Project. In this paper, numerical simulation and experiment for the hollow part with four arc-typed cross-section are mainly studied. The research provides theoretic foundation for the spinning forming method and forming mechanism of the other kinds of non-circular cross-section hollow parts. The main research contents as follows,
Firstly, this paper analyzes the spinning forming process of the hollow part with four arc-typed cross-section. And based on the three-dimensional software Pro/e and the motion simulation software ADAMS, the roller motion trail is got. Then this paper builds the FEM model with the software MSC.MARC.
Secondly, this paper analyzes the FEM simulation with the FEM simulation results, and the analysis of the contents are stress and strain distributions, the influences of the main process parameters on the forming quality of the workpiece.
Thirdly, this paper compares the stress and strain distributions and the differences of the influences on the main process parameters of the hollow parts with three and four arc-typed cross-section.
Fourth, based on the structure of HGPX-WSM machine and the designing method of the exploratory surface of the hollow parts with three arc-typed cross-section, this paper analyzes and compares the exploratory surfaces designed by the analysis method and the method of B-spine curves fitting of the scatter data. Above all, the two exploratory surfaces with the two methods are designed and the error distribution curve is analyzed. Finally, this paper chooses the method of B-spine curves fitting of the scatter data.
Fifth, with the result of the numerical simulation analysis as the direction, using the HGPX-WSM machine, do the experiment. Then, the effects of the main process parameters, such as feed rate and spindle speed are also explicated, and the influence laws are obtained. At the same time, this paper compares the theoretical results with the test results which confirms the reliability of numerical simulation.
本课题来源于国家自然科学基金项目(50775076)“非圆截面空心零件旋压成形方法及变形机理研究”。论文主要以四边圆弧形横截面空心零件为研究对象,对其旋压成形的数值模拟及试验进行研究,为后续多种非圆横截面空心零件旋压成形方法以及旋压成形机理的探索奠定基础。主要内容如下:
1、分析四边圆弧形横截面空心零件的旋压成形工艺,结合三维软件Pro/e以及运动仿真软件ADAMS获得旋轮运动轨迹,运用MSC.MARC软件建立有限元数值模型;
2、对有限元数值模拟结果进行分析,主要分析的内容:应力应变分布规律、主要工艺参数对工件成形质量的影响;
3、比较三边圆弧形和四边圆弧形横截面空心零件旋压成形的应力应变分布规律,以及主要工艺参数对两者成形质量影响规律的差异性;
4、结合HGPX-WSM机床结构,并且在三边圆弧形横截面空心零件旋压靠模型面的设计方法的基础上,分析并且比较解析法和离散数据点的B样条曲线拟合法设计的靠模型面。首先采用这两种方法分别设计出靠模型面,然后运用ADAMS软件分析靠模型面的误差大小以及误差分布,最终选择离散数据点的B样条曲线拟合法;
5、以数值模拟分析结果为指导,使用HGPX-WSM型多功能卧式数控旋压机,进行四边圆弧形横截面空心零件单道次拉深旋压工艺试验。研究旋轮轴向进给比、主轴转速等工艺参数对旋压件成形质量的影响规律。同时将试验结果和模拟结果进行比较,验证有限元模型的合理性。
Spinning is widely used in the field of metal forming, not only with the advantages of high forming precision, low cost and high quality, but also it can bring multiple benefits such as environmental protection, economy and so on. In recent years, some of the hollow parts with non-circular section can be produced by spinning, which breaks through the limit of spinning only producing hollow parts with circular section.
This paper is financially supported by the project“Research on spinning forming method and deformation mechanism of the hollow part with non-circular section”(50775076), which is a National Natural Scientific Fund Project. In this paper, numerical simulation and experiment for the hollow part with four arc-typed cross-section are mainly studied. The research provides theoretic foundation for the spinning forming method and forming mechanism of the other kinds of non-circular cross-section hollow parts. The main research contents as follows,
Firstly, this paper analyzes the spinning forming process of the hollow part with four arc-typed cross-section. And based on the three-dimensional software Pro/e and the motion simulation software ADAMS, the roller motion trail is got. Then this paper builds the FEM model with the software MSC.MARC.
Secondly, this paper analyzes the FEM simulation with the FEM simulation results, and the analysis of the contents are stress and strain distributions, the influences of the main process parameters on the forming quality of the workpiece.
Thirdly, this paper compares the stress and strain distributions and the differences of the influences on the main process parameters of the hollow parts with three and four arc-typed cross-section.
Fourth, based on the structure of HGPX-WSM machine and the designing method of the exploratory surface of the hollow parts with three arc-typed cross-section, this paper analyzes and compares the exploratory surfaces designed by the analysis method and the method of B-spine curves fitting of the scatter data. Above all, the two exploratory surfaces with the two methods are designed and the error distribution curve is analyzed. Finally, this paper chooses the method of B-spine curves fitting of the scatter data.
Fifth, with the result of the numerical simulation analysis as the direction, using the HGPX-WSM machine, do the experiment. Then, the effects of the main process parameters, such as feed rate and spindle speed are also explicated, and the influence laws are obtained. At the same time, this paper compares the theoretical results with the test results which confirms the reliability of numerical simulation.
引文
[1]汪大年.金属塑性成形原理[M] .北京,机械工业出版社,1994:1-5
[2]王成和,刘克璋.旋压技术[M].北京:机械工业出版社.1986:27-51
[3]赵文豪.旋压技术现状[J].锻压技术,2005(5):95-100
[4]王玉辉,夏琴香,杨明辉等.数控旋压机床的发展历程及其研究现状[J].锻压技术,2006,30(4):97-99
[5]陈家华.单旋轮无芯模缩径旋压成形的数值模拟与工艺研究[D].华南理工大学硕士学位论文,2006
[6]赵文豪,李彦利.旋压技术与应用[M].北京,机械工业出版社,2008:7-8
[7]夏琴香,张赛军,梁佰祥,任晓龙,阮锋.三维非轴对称偏心类管件旋压成形时的变形分析.机械工程学报,2005年10月,第41卷第10期:P200-204.
[8] M. Hayama, H. Kudo. Analysis of diametrical growth and working forces in tube spinning. Bulletin of Japan Society of Mechanical Engineers. 1979,Vol.22:P776-784.
[9] M.D.Chen, R.Q.Hsu, K.H.Fuh. Forecast of shear spinning force and surface roughness of spun cones by employing regression analysis. International Journal of Machine Tools & Manufacture. 2001, Vol.41:P1721-1734.
[10]夏琴香.三维非轴对称偏心及倾斜管件缩径旋压成形理论与方法研究[D].华南理工大学博士学位论文. 2006年4月.
[11] MJC Engineering and Technology, Inc., Homepage, 31. 2005
[12]张帅斌.三角形截面空心零件旋压工艺研究及有限元数值模拟[D] .广州,华南理工大学,2009:1
[13]詹欣溪.三角形横截面空心零件旋压成形方法及旋压力试验研究[D].广州,华南理工大学,2009
[14]夏琴香,詹欣溪,张帅斌等.三边圆弧型等距截面空心零件旋轮运动轨迹的设计,现代制造工程[J],2008,(6):78-79
[15]佚名. SHEETS Manufacturing Company Homepage2Ap2plications2Flexibility in Part Design [ EB/ OL ] . [ 2005203231 ] http :/ / www. sheet smfg. com/ applications. html.
[16] T.Amano,K.Tamura. The study of an elliptical cone spinning by the trial equipment. Proceedings of the 3rd International Conference on Rotary Metalworking Processes:P312-324
[17] Xi-Cheng Gao,Da-Chang Kanga,Xiao-Feng Menga. Experimental research on a newtechnology of ellipse spinning. Journal of Materials Processing Technology 94(1999)197-200
[18]刘兴家.承压椭圆封头旋轮三目标优化的研究.塑性工程学报,2001第3期:P80-84
[19] B. Awiszus, F. Meyer. Metal spinning of non-circular hollow parts. Proceedings of the 8th International Conference on Technology of Plasticity, Verona, Italy, 9-13, October, 2005:P353-355.
[20] Arai, H. Robotic Metal Spinning Forming Non-axisymmetric Products Using Force Control. Proceedings of the 2005 IEEE International Conference on Robotics and Automation, Barcelona, Spain, April 2005:2691-2696.
[21] Ichiro Shimizu. Asymmetric forming of aluminum sheets by synchronous spinning. http://www.elsevier.com/locate/jmatprotec
[22]程秋谋,康达昌等.椭圆异形件旋压工艺的研究[J].塑性工程学报,1997,4(1):56-59
[23]张力宏,吴江等.不锈钢薄壁管滚珠旋压模拟及缺陷分析.航天制造技术,2008(1):5-9
[24]詹梅,李虎等.大型复杂薄壁壳体多道次旋压过程中的壁厚变化.塑性工程学报,2008(2):115-121
[25]李灵凤.药型罩强力旋压的数值模拟结构分析.特种成形. 2008,(2):85-87
[26]徐银丽,詹梅等.锥形件变薄旋压回弹的三维有限元分析.材料科学与工艺,2008(2):167-171
[27]夏琴香,梁佰祥等,倾斜类管件单道次缩径旋压的数值模拟.华南理工大学学报,2006(6):115-121
[28]夏琴香,邝卫华等.筒形件三旋轮缩径旋压过程的数值模拟.锻压技术,2005(1):44-46
[29]杜平安,甘娥忠,于亚婷编著.有限元法-原理、建模及应用[M].北京:国防工业出版社,2004:4-10
[30]应富强,张更超,潘孝勇.三维有限元模拟技术在金属塑性成形中的应用[J].锻压装备与制造技术,2003(5):10-13
[31]李亚智,赵美英等.有限元法基础与程序设计[M].北京:科学出版社,2004
[32]孟凡中.弹塑性有限变形理论和有限单元方法.清华大学出版社, 1985
[33]尚越.杯形薄壁梯形内齿旋压成形方法及试验研究[D] .广州,华南理工大学,2008:10
[34]姜晋庆张锴.结构弹塑性有限元分析法.北京:字航出版社,1990
[35]赵祖武著.塑性理论基础.北京:人民教育出版社,1963
[36]李大潜.有限元素法续讲.北京:科学出版社,1979
[37]徐文臣.小锥角零件多道次剪旋试验研究及工艺参数优化. [工学硕士学位论文],哈尔滨工业大学,2001
[38]郑岩,顾松东,吴斌. Marc 2001从入门到精通.北京[M]:中国水利水电出版社. 2003
[39]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,2004:1-6
[40]李军,刑俊文,覃文浩,等编.ADAMS实例教程[M].北京:北京理工大学出版社,2002
[41]邬义杰.多面形非圆型面设计方法及数控加工原理研究.浙江大学学报. 2004(7):878-879
[42]邱家骏.工程力学[M] .北京:机械工业出版社,2004
[43]夏琴香,胡昱,孙凌燕等.旋轮型面对矩形内齿旋压成形影响的数值模拟[J].华南理工大学学报,2007,35(8):1-2
[44]秦成.基于Pro/e和ADAMS的凸轮机构虚拟样机研究[J].机械工程与自动化,2008,(17):35-36
[45]刘建生,陈慧琴,郭晓霞.金属塑性加工有限元模拟技术与应用.北京:冶金工业出版社,2003.
[46]李尚健.金属塑性成形过程模拟[M].北京:机械工业出版社,1999年
[47]夏琴香,阮锋等.锥形件柔性旋压成形质量的研究.锻压技术,2003(1):35-37.
[48] Piegl 1. Interactive Data Interpolation by Rational Bezier Curves[J]. IEEE Comput. Graphics Appl,Apr,1987:45-58
[49]Provilids.Curves Fitting with Conic Splines[J]. ACM Trans. Graphics,2,1983:1-31
[50] L.S. Curve Fitting with Bezier Cubics[J]. Graphics Model and Image Preocessing. 1996,58:223-232
[51]朱浩,方宗德,胡鑫.离散数据点的B样条曲线精确拟合.机械科学与技术,2000(19):119-121
[2]王成和,刘克璋.旋压技术[M].北京:机械工业出版社.1986:27-51
[3]赵文豪.旋压技术现状[J].锻压技术,2005(5):95-100
[4]王玉辉,夏琴香,杨明辉等.数控旋压机床的发展历程及其研究现状[J].锻压技术,2006,30(4):97-99
[5]陈家华.单旋轮无芯模缩径旋压成形的数值模拟与工艺研究[D].华南理工大学硕士学位论文,2006
[6]赵文豪,李彦利.旋压技术与应用[M].北京,机械工业出版社,2008:7-8
[7]夏琴香,张赛军,梁佰祥,任晓龙,阮锋.三维非轴对称偏心类管件旋压成形时的变形分析.机械工程学报,2005年10月,第41卷第10期:P200-204.
[8] M. Hayama, H. Kudo. Analysis of diametrical growth and working forces in tube spinning. Bulletin of Japan Society of Mechanical Engineers. 1979,Vol.22:P776-784.
[9] M.D.Chen, R.Q.Hsu, K.H.Fuh. Forecast of shear spinning force and surface roughness of spun cones by employing regression analysis. International Journal of Machine Tools & Manufacture. 2001, Vol.41:P1721-1734.
[10]夏琴香.三维非轴对称偏心及倾斜管件缩径旋压成形理论与方法研究[D].华南理工大学博士学位论文. 2006年4月.
[11] MJC Engineering and Technology, Inc., Homepage, 31. 2005
[12]张帅斌.三角形截面空心零件旋压工艺研究及有限元数值模拟[D] .广州,华南理工大学,2009:1
[13]詹欣溪.三角形横截面空心零件旋压成形方法及旋压力试验研究[D].广州,华南理工大学,2009
[14]夏琴香,詹欣溪,张帅斌等.三边圆弧型等距截面空心零件旋轮运动轨迹的设计,现代制造工程[J],2008,(6):78-79
[15]佚名. SHEETS Manufacturing Company Homepage2Ap2plications2Flexibility in Part Design [ EB/ OL ] . [ 2005203231 ] http :/ / www. sheet smfg. com/ applications. html.
[16] T.Amano,K.Tamura. The study of an elliptical cone spinning by the trial equipment. Proceedings of the 3rd International Conference on Rotary Metalworking Processes:P312-324
[17] Xi-Cheng Gao,Da-Chang Kanga,Xiao-Feng Menga. Experimental research on a newtechnology of ellipse spinning. Journal of Materials Processing Technology 94(1999)197-200
[18]刘兴家.承压椭圆封头旋轮三目标优化的研究.塑性工程学报,2001第3期:P80-84
[19] B. Awiszus, F. Meyer. Metal spinning of non-circular hollow parts. Proceedings of the 8th International Conference on Technology of Plasticity, Verona, Italy, 9-13, October, 2005:P353-355.
[20] Arai, H. Robotic Metal Spinning Forming Non-axisymmetric Products Using Force Control. Proceedings of the 2005 IEEE International Conference on Robotics and Automation, Barcelona, Spain, April 2005:2691-2696.
[21] Ichiro Shimizu. Asymmetric forming of aluminum sheets by synchronous spinning. http://www.elsevier.com/locate/jmatprotec
[22]程秋谋,康达昌等.椭圆异形件旋压工艺的研究[J].塑性工程学报,1997,4(1):56-59
[23]张力宏,吴江等.不锈钢薄壁管滚珠旋压模拟及缺陷分析.航天制造技术,2008(1):5-9
[24]詹梅,李虎等.大型复杂薄壁壳体多道次旋压过程中的壁厚变化.塑性工程学报,2008(2):115-121
[25]李灵凤.药型罩强力旋压的数值模拟结构分析.特种成形. 2008,(2):85-87
[26]徐银丽,詹梅等.锥形件变薄旋压回弹的三维有限元分析.材料科学与工艺,2008(2):167-171
[27]夏琴香,梁佰祥等,倾斜类管件单道次缩径旋压的数值模拟.华南理工大学学报,2006(6):115-121
[28]夏琴香,邝卫华等.筒形件三旋轮缩径旋压过程的数值模拟.锻压技术,2005(1):44-46
[29]杜平安,甘娥忠,于亚婷编著.有限元法-原理、建模及应用[M].北京:国防工业出版社,2004:4-10
[30]应富强,张更超,潘孝勇.三维有限元模拟技术在金属塑性成形中的应用[J].锻压装备与制造技术,2003(5):10-13
[31]李亚智,赵美英等.有限元法基础与程序设计[M].北京:科学出版社,2004
[32]孟凡中.弹塑性有限变形理论和有限单元方法.清华大学出版社, 1985
[33]尚越.杯形薄壁梯形内齿旋压成形方法及试验研究[D] .广州,华南理工大学,2008:10
[34]姜晋庆张锴.结构弹塑性有限元分析法.北京:字航出版社,1990
[35]赵祖武著.塑性理论基础.北京:人民教育出版社,1963
[36]李大潜.有限元素法续讲.北京:科学出版社,1979
[37]徐文臣.小锥角零件多道次剪旋试验研究及工艺参数优化. [工学硕士学位论文],哈尔滨工业大学,2001
[38]郑岩,顾松东,吴斌. Marc 2001从入门到精通.北京[M]:中国水利水电出版社. 2003
[39]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,2004:1-6
[40]李军,刑俊文,覃文浩,等编.ADAMS实例教程[M].北京:北京理工大学出版社,2002
[41]邬义杰.多面形非圆型面设计方法及数控加工原理研究.浙江大学学报. 2004(7):878-879
[42]邱家骏.工程力学[M] .北京:机械工业出版社,2004
[43]夏琴香,胡昱,孙凌燕等.旋轮型面对矩形内齿旋压成形影响的数值模拟[J].华南理工大学学报,2007,35(8):1-2
[44]秦成.基于Pro/e和ADAMS的凸轮机构虚拟样机研究[J].机械工程与自动化,2008,(17):35-36
[45]刘建生,陈慧琴,郭晓霞.金属塑性加工有限元模拟技术与应用.北京:冶金工业出版社,2003.
[46]李尚健.金属塑性成形过程模拟[M].北京:机械工业出版社,1999年
[47]夏琴香,阮锋等.锥形件柔性旋压成形质量的研究.锻压技术,2003(1):35-37.
[48] Piegl 1. Interactive Data Interpolation by Rational Bezier Curves[J]. IEEE Comput. Graphics Appl,Apr,1987:45-58
[49]Provilids.Curves Fitting with Conic Splines[J]. ACM Trans. Graphics,2,1983:1-31
[50] L.S. Curve Fitting with Bezier Cubics[J]. Graphics Model and Image Preocessing. 1996,58:223-232
[51]朱浩,方宗德,胡鑫.离散数据点的B样条曲线精确拟合.机械科学与技术,2000(19):119-121