五边形截面空心零件旋压成形数值模拟与工艺研究
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摘要
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”。为了推广非圆旋压的应用领域及加深理论研究,本论文主要以五边形横截面空心零件为研究对象,对其旋压成形过程进行数值模拟及试验研究,主要工作如下:
1、运用ADAMS求出五边形截面空心零件旋压成形的旋轮轨迹,并分析相应的参数设置。运用MSC.MARC建立五边形截面空心零件旋压成形的有限元数值模型,对有限元建模网格的划分、时间步长的设定及常见错误类型等进行了探讨。
2、对比分析不同形状的五边形零件与不同边数的圆弧形零件旋压成形后的应力应变分布情况,研究非圆截面空心零件旋压成形的特点。基于正交试验分析了主要工艺参数对工件最大减薄率及最大旋压力的影响规律;并通过单因素的数值模拟研究了主要工艺参数对五直边圆弧形零件的壁厚分布及回弹角的影响规律。
3、通过分析旋压过程旋轮与芯模的接触情况及偏差,对比非对称解析法与离散数据点的B样条曲线拟合法所设计靠模型面的误差。由于这两种方法的误差较大,结合误差的特点研制出“虚设滚子法”,经验证该方法较为灵活,且误差较小。
4、通过对比零件的外形尺寸、壁厚分布及旋压力的结果,验证了所建模拟与试验相符合。采用正交试验验证了影响壁厚最大减薄率的主次因素为:相对高度>旋轮圆角半径>进给比。对三向旋压力进行测量,并分析了主要工艺参数对轴向旋压力的影响。
综上所述,本文利用数值模拟与工艺试验相结合的方法,探索出了五直边圆弧形截面空心零件旋压的成形机理,达到了理论指导实践、预防产品缺陷的目的。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,其研究具有较高的理论意义和实践应用价值。
This paper is financially supported by the National Natural Science Foundation of China“Research on spinning forming method and deformation mechanism of the hollow part with non-circular section”(No. 50775076). In order to spread the application of non-circular cross-section part spinning and enhance the theory research., the numerical simulations and experiments for the pentagonal cross-section hollow-parts were mainly studied, the following works were carried out:
Firstly, the pentagonal cross-section hollow-parts spinning FEM models with MSC.MARC was built, and the meshing, step time setting and some Exit numbers in building the models was analyzed. ADAMS was ddopted to solve the roller’s track of pentagonal cross-section hollow-parts spinning, and the setting of relevant parameters were discussed. Secondly, compared the stress-strain distribution of different kinds of pentagonal cross-section hollow-parts spinning, and different arc cross-section parts, try to research the mechanism of non-circular cross-section parts spinning. Based on orthogonal test method to analyze the influence laws of main parameter effected the maximum thickness reduction and maximum spinning force; from single factor to analyze the parameter affected of wall thickness distribution and rebound angle.
Thirdly, analyzed the roller and mandrel’s contact situation and deviation, compared the errors of profiling mandrel designed by the asymmetry analysis method and the method of B-spine curves fitting of the scatter data. The error both are too large, then develop the“nominal roller method”, after validate the method is agility and tiny error.
Fourthly, compared the outline, thickness distribution and spinning force to validate simulation is consistent with experiment. Based on orthogonal test, the influence sequence on the maximum thickness reduction being the relative height of workpiece, feed rate and roundness radius of roller was validated. Measured the three directions spinning force Fn, Fz and Fy, and then analyzed the parameters influence law of axial spinning force Fz.
To sum up, this paper through the numerical simulation and the technology testing, obtained the spinning forming theory of the pentagonal cross-section hollow-part, and the project of spinning faults prevention is realized. The research provides theoretic foundation for the spinning forming method and forming mechanism of the other kinds of non-circular cross-section hollow parts. This paper is valuable on both theory and practical application.
1、运用ADAMS求出五边形截面空心零件旋压成形的旋轮轨迹,并分析相应的参数设置。运用MSC.MARC建立五边形截面空心零件旋压成形的有限元数值模型,对有限元建模网格的划分、时间步长的设定及常见错误类型等进行了探讨。
2、对比分析不同形状的五边形零件与不同边数的圆弧形零件旋压成形后的应力应变分布情况,研究非圆截面空心零件旋压成形的特点。基于正交试验分析了主要工艺参数对工件最大减薄率及最大旋压力的影响规律;并通过单因素的数值模拟研究了主要工艺参数对五直边圆弧形零件的壁厚分布及回弹角的影响规律。
3、通过分析旋压过程旋轮与芯模的接触情况及偏差,对比非对称解析法与离散数据点的B样条曲线拟合法所设计靠模型面的误差。由于这两种方法的误差较大,结合误差的特点研制出“虚设滚子法”,经验证该方法较为灵活,且误差较小。
4、通过对比零件的外形尺寸、壁厚分布及旋压力的结果,验证了所建模拟与试验相符合。采用正交试验验证了影响壁厚最大减薄率的主次因素为:相对高度>旋轮圆角半径>进给比。对三向旋压力进行测量,并分析了主要工艺参数对轴向旋压力的影响。
综上所述,本文利用数值模拟与工艺试验相结合的方法,探索出了五直边圆弧形截面空心零件旋压的成形机理,达到了理论指导实践、预防产品缺陷的目的。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,其研究具有较高的理论意义和实践应用价值。
This paper is financially supported by the National Natural Science Foundation of China“Research on spinning forming method and deformation mechanism of the hollow part with non-circular section”(No. 50775076). In order to spread the application of non-circular cross-section part spinning and enhance the theory research., the numerical simulations and experiments for the pentagonal cross-section hollow-parts were mainly studied, the following works were carried out:
Firstly, the pentagonal cross-section hollow-parts spinning FEM models with MSC.MARC was built, and the meshing, step time setting and some Exit numbers in building the models was analyzed. ADAMS was ddopted to solve the roller’s track of pentagonal cross-section hollow-parts spinning, and the setting of relevant parameters were discussed. Secondly, compared the stress-strain distribution of different kinds of pentagonal cross-section hollow-parts spinning, and different arc cross-section parts, try to research the mechanism of non-circular cross-section parts spinning. Based on orthogonal test method to analyze the influence laws of main parameter effected the maximum thickness reduction and maximum spinning force; from single factor to analyze the parameter affected of wall thickness distribution and rebound angle.
Thirdly, analyzed the roller and mandrel’s contact situation and deviation, compared the errors of profiling mandrel designed by the asymmetry analysis method and the method of B-spine curves fitting of the scatter data. The error both are too large, then develop the“nominal roller method”, after validate the method is agility and tiny error.
Fourthly, compared the outline, thickness distribution and spinning force to validate simulation is consistent with experiment. Based on orthogonal test, the influence sequence on the maximum thickness reduction being the relative height of workpiece, feed rate and roundness radius of roller was validated. Measured the three directions spinning force Fn, Fz and Fy, and then analyzed the parameters influence law of axial spinning force Fz.
To sum up, this paper through the numerical simulation and the technology testing, obtained the spinning forming theory of the pentagonal cross-section hollow-part, and the project of spinning faults prevention is realized. The research provides theoretic foundation for the spinning forming method and forming mechanism of the other kinds of non-circular cross-section hollow parts. This paper is valuable on both theory and practical application.
引文
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[3]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
[4]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
[5]张涛.旋压成形工艺[M].北京,化学工业出版社,2008:2-7
[6]赵文豪,李彦利.旋压技术与应用[M].北京,机械工业出版社,2008:1-12
[7]杨明辉,梁佰祥,夏琴香,阮锋.旋压技术分类及应用[J].机电工程技术. 2004, 33(11):14-16
[8]夏琴香.三维非轴对称零件旋压成形机理研究[J].机械工程学报. 2004, 40(2): 153-156.
[9]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[J].机械工程学报,2005年10月,第41卷第10期:P200-204.
[10] M. Hayama, H. Kudo. Analysis of diametrical growth and working forces in tube spinning[J]. Bulletin of Japan Society of Mechanical Engineers. 1979,Vol.22:P776-784.
[11] M.D.Chen, R.Q.Hsu, K.H.Fuh. Forecast of shear spinning force and surface roughness of spun cones by employing regression analysis[J]. International Journal of Machine Tools & Manufacture. 2001, Vol.41:P1721-1734.
[12]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.
[13]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,2009.6
[14] Hirohiko Arai. Robotic Metal Spinning- Shear Spinning Using Force Feedback Control[C]. Proceedings of the 2003 IEEE loiernstional Conference on Robotics &Automation Taipei, Taiwan, September 14-19, 2003
[15] Arai, H. Robotic Metal Spinning Forming Non-axisymmetric Products Using Force Control[C]. Proceedings of the 2005 IEEE International Conference on Robotics andAutomation, Barcelona, Spain, April 2005:2691-2696.
[16] Hirohiko Arai. Force-controlled Metal Spinning Machine Using Linear Motors[C]. Proceedings of the 2006 IEEE International Conference on Robotics and Automation Orlando, Florida - May 2006.
[17] Akio Sekiguchi, Hirohiko Arai.Synchronous die-less spinnning of curved products[J].Steel Research International, Volume 81, Number 9, 2010: P1010-1013.
[18] B. Awiszus, F. Meyer. Metal spinning of non-circular hollow parts[C]. Proceedings of the 8th International Conference on Technology of Plasticity, Verona, Italy, 9-13, October, 2005:P353-355.
[19] MJC Engineering and Technology, Inc., Homepage, 31. 2005
[20] Sebastian Hartel, Birgit Awiszus.Numerical and experimental investigaitions of production of non-rotationally symmetric hollow parts using sheet metal spinning[J]. Steel Research International, Volume 81, Number 9, 2010: P998-1001.
[21] T.Amano,K.Tamura. The study of an elliptical cone spinning by the trial equipment[C]. Proceedings of the 3rd International Conference on Rotary Metalworking Processes:P312-324
[22] Xi-Cheng Gao,Da-Chang Kanga,Xiao-Feng Menga. Experimental research on a new technology of ellipse spinning[J]. Journal of Materials Processing Technology 94(1999)197-200
[23] Ichiro Shimizu. Asymmetric forming of aluminum sheets by synchronous spinning[J]. Journal of Materials Processing Technology 210 (2010) 585–592
[24]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
[25]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
[26]吴小瑜.四弧边圆弧形横截面空心零件旋压成形数值模拟及试验研究[D].广州,华南理工大学,2010
[27]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
[28]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
[29]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
[30]孟凡中.弹塑性有限变形理论和有限单元方法[M].北京:清华大学出版社, 1985
[31]刘劲松,张世宏等著. MSC.MARC在材料加工工程中的应用[M].北京:中国水利水电出版社,2010
[32]郑建荣. ADAMS—虚拟样机技术入门与提高[M].北京:机械工业出版社,2002.
[33] CHENG Chonggong. Analysis of Movement Warp of the CAM Mechanism For Matched Gas in the Gas-engine. Journal of Changsha University[J]. 2002,No 04:P47-49.
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