大尺寸薄壁管材滚珠旋压成形研究
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摘要
现代旋压是一种先进的金属塑性加工技术,在航天、航空、军工等领域中得到了日益广泛的应用。然而实际生产中影响产品质量的因素很多,各参数之间的合理搭配需要人员反复摸索调试,有限元数值模拟技术可改善这一过程。本文采用数值模拟方法和实验技术对薄壁管材滚珠旋压成形工艺展开了研究,论文主要结果如下：
(1)基于DEFORM-3D有限元平台,建立了滚珠旋压过程的有限元模型,分析了工艺参数如减薄率、轴向进给比和滚珠工作角对成形质量的影响规律,经过理论和实验参数对比分析,获得了合理的旋压工艺参数：减薄率Ψt=25-30%,轴向进给比f=0.5～1.0mm/r,滚珠工作角20°左右。
(2)对大直径(300mm)GH4169管材滚珠旋压成形过程进行了研究,分析了旋压过程中金属的流动规律。通过模拟多道次旋压成形过程,分析了各道次工艺参数对成形效果的影响,探讨了成形的可能性。就轴向进给比、滚珠直径和减薄率对大直径管材成形的影响进行数值分析,得到了一定结果。
(3)对管材滚珠旋压力进行了理论计算,分析接触变形力条件,推导出接触变形压力计算公式,确定了管材滚珠旋压力理论计算物理模型,并比较分析了数值模拟结果和物理模型计算结果的差异,给出该旋压力计算模型的应用范围。
(4)完成了GZ300型号的管材滚珠旋压机设计工作,设计主要部件包括旋压机油缸设计、电动机及带传动和整体模具设计。确定了旋压机的主要参数,其中包括旋压机压力机最大行程,工件最大直径,工件最大长度,工件最大壁厚等。
Modern spinning,used as an advanced plastic forming technology,has been widely applied to many fields,such as Aeronautics,Astronautics and Weaponry,etc.However,in the process of manufacture,many process parameters affect the qualities of spinned parts,people have to establish process parameters by trial-and-error approach,this process can be improved by the finite element numerical simulation technology.In this paper,research is carried out by numerical simulation and experiment technology for ball spinning forming process of thin-wall tubes,its main results are as follows:
(1) Based on DEFORM-3D finite element platform, finite element model of ball spinning process is established. The influence law of forming quality with process parameters such as thinning ratio, axial feeding ratio and ball working angle is analyzed,through theoretical and experimental parameters comparative analysis,there are reasonable spinning craft parameters:thinning ratio=25-30%,axial feeding ratio f=0.5-1.0mm/r,ball working angle 20°.
(2) Ball spinning forming process in GH4169 large diameter(300mm)tubing has been studied,metal flow pattern of spinning process has been analyzed.Multipass spinning forming process and each lane process parameters on forming effect are simulated,the possibility of forming is discussed.The influence of the axial feeding ratio, ball diameter and thinning ratio on the large diameter tubing forming is on numerical analysis,and gain some law.
(3) The theory research on calculation of the tubing ball spinning pressure is carried through,and analysis the conditions of the contact deforming force. The calculation formula of contact deforming pressure is derivated,then the physical model of theoretical calculation for the tubing ball spinning is determined.There are compared differences between the numerical simulation results and the physical model calculation results,so range of applications with the spinning force calculation model is given.
(4) The design work for GZ300 models of tubing ball spinning is completed,design for main components is included of cylinder design,motor with belt transmission and the whole mold design.The main parameters for spinning machine have been determined including the longest press trip of the spinning machine,the biggest diameter of the workpiece,the maximum length of the workpiece and the maximum thickness of the workpiece.
(1)基于DEFORM-3D有限元平台,建立了滚珠旋压过程的有限元模型,分析了工艺参数如减薄率、轴向进给比和滚珠工作角对成形质量的影响规律,经过理论和实验参数对比分析,获得了合理的旋压工艺参数：减薄率Ψt=25-30%,轴向进给比f=0.5～1.0mm/r,滚珠工作角20°左右。
(2)对大直径(300mm)GH4169管材滚珠旋压成形过程进行了研究,分析了旋压过程中金属的流动规律。通过模拟多道次旋压成形过程,分析了各道次工艺参数对成形效果的影响,探讨了成形的可能性。就轴向进给比、滚珠直径和减薄率对大直径管材成形的影响进行数值分析,得到了一定结果。
(3)对管材滚珠旋压力进行了理论计算,分析接触变形力条件,推导出接触变形压力计算公式,确定了管材滚珠旋压力理论计算物理模型,并比较分析了数值模拟结果和物理模型计算结果的差异,给出该旋压力计算模型的应用范围。
(4)完成了GZ300型号的管材滚珠旋压机设计工作,设计主要部件包括旋压机油缸设计、电动机及带传动和整体模具设计。确定了旋压机的主要参数,其中包括旋压机压力机最大行程,工件最大直径,工件最大长度,工件最大壁厚等。
Modern spinning,used as an advanced plastic forming technology,has been widely applied to many fields,such as Aeronautics,Astronautics and Weaponry,etc.However,in the process of manufacture,many process parameters affect the qualities of spinned parts,people have to establish process parameters by trial-and-error approach,this process can be improved by the finite element numerical simulation technology.In this paper,research is carried out by numerical simulation and experiment technology for ball spinning forming process of thin-wall tubes,its main results are as follows:
(1) Based on DEFORM-3D finite element platform, finite element model of ball spinning process is established. The influence law of forming quality with process parameters such as thinning ratio, axial feeding ratio and ball working angle is analyzed,through theoretical and experimental parameters comparative analysis,there are reasonable spinning craft parameters:thinning ratio=25-30%,axial feeding ratio f=0.5-1.0mm/r,ball working angle 20°.
(2) Ball spinning forming process in GH4169 large diameter(300mm)tubing has been studied,metal flow pattern of spinning process has been analyzed.Multipass spinning forming process and each lane process parameters on forming effect are simulated,the possibility of forming is discussed.The influence of the axial feeding ratio, ball diameter and thinning ratio on the large diameter tubing forming is on numerical analysis,and gain some law.
(3) The theory research on calculation of the tubing ball spinning pressure is carried through,and analysis the conditions of the contact deforming force. The calculation formula of contact deforming pressure is derivated,then the physical model of theoretical calculation for the tubing ball spinning is determined.There are compared differences between the numerical simulation results and the physical model calculation results,so range of applications with the spinning force calculation model is given.
(4) The design work for GZ300 models of tubing ball spinning is completed,design for main components is included of cylinder design,motor with belt transmission and the whole mold design.The main parameters for spinning machine have been determined including the longest press trip of the spinning machine,the biggest diameter of the workpiece,the maximum length of the workpiece and the maximum thickness of the workpiece.
引文
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[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)：27-28
[4]牟少正,韩冬.有色金属旋压技术研究现状[J].航天制造技术。2008.(8)4：38-43
[5]王成和,刘克璋.旋压技术.北京：机械工业出版社,1986
[6]赵云豪.我国旋压材料与产品的概述.全国第十届旋压技术交流大会论文汇编：9-15
[7]赵琳瑜,韩冬等.典型零件旋压成形技术应用发展.航天制造技术,2007.2：5-10
[8]赵云豪,李彦利.旋压技术与应用.北京：机械工业出版社,2007
[9]董湘怀,塑性加工技术的发展趋势.中国机械工程,2000.(9)：1074-1077
[10]仲町英治.基于有限元分析及非线性规划的金属成形过程优化设计.中国机械工程,1997.8(8)：21-26
[11]董湘怀,仲町英治.晶体塑性模型在板材成形计算机模拟中的应用.中国机械工程,1997,8(8)：27-30
[12]陈家华.数值模拟方法在旋压技术中的应用.机电工程技术,2005.(2)：11-13
[13]高西成,康达昌.薄壁筒收口旋压过程的数值模拟.塑性工程学报,1999.(4)：54-57
[14]苏畅.厚壁封头温旋成形的数值模拟.燕山大学硕士毕业.2001
[15]周照耀,王真,赵宪明等.筒形件强力旋压的刚塑性有限元分析.塑性工程学报,1994.(3)：37-42
[16]李克智,李贺军等.筒形件反旋时工艺参数对残余应力分布的影响.锻压技术,1997.(4)：23-25
[17]杨英丽,郭荻子等.我国钛旋压技术研究进展[J].航空制造技术,2007.增刊： 493-497
[18]李继贞,李志强.我国旋压技术的现状与发展[J].全国第十届旋压技术交流大会论文汇编：5-8
[19]张士宏,吴江.薄壁不锈钢管滚珠旋压成形工艺研究.锻压技术,2009.34(1)：60-64
[20]王淼,王忠堂,王本贤,等.轴向进给比对薄壁管滚珠旋压影响的有限元分析.沈了理工大学学报,2007.26(2)：30-33
[21]Jiang S Y, Ren Z Y. Analysis of mechanics in ball spinning of thin-walled tube Chinese Journal of Mechanical Engi-neering,2008.21(1):25-30
[22]江树勇,顾卫东,李春峰,等.纵向内筋薄壁筒反向滚珠旋压成形机理研究.锻压技术,2008.33(5)：88-91
[23]Jiang S Y, Zheng Y F, Ren Z Y, et al. Multi-pass spinning ofthin-walled tubular part with longitudinal inner rib.Transactions of Nonferrous Metals Society of China,2009.19(1):215-221
[24]Jiang S Y, Xue K M, Li C F, et al. Spinning deformation cri-teria of thin-walled tubular part with longitudinal inner ribs. Journal of Wuhan University Technology-Mater Sci Ed,2006.21(4):169-172
[25]Jiang S Y, Ren Z Y, Xue K M, et al. Application of BPANNfor prediction of backward ball spinning of thin-walled tubularpart with longitudinal inner ribs [J]. Journal of MaterialsProcessing Technology,2008.196(1-3):190-196
[26]李茂盛,康达昌,张士宏等.滚珠旋压工艺中成形区接触压力的分析计算[J].材料科学与工艺,2004.12(2)：125-128
[27]夏琴香.三维非轴对称零件旋压成形工艺及设备.新技术新工艺,2003.(12)：33-35
[28]王成和,刘克璋等.旋压技术.北京：机械工业出版社.1986
[29]日本塑性加工学会.旋压成形技术.北京：机械工业出版社,1988
[30]陈适先,贾文铎等.强力旋压工艺与设备.北京：国防工业出版社,1986
[31]Wong C C, Dean T A, Lin J.A Review of Spinning, Shear Forming and FlowForming Proeess[J].International Journal of Maehine Tools&Manufaeture, 2003.(4):1419-1435
[32]F. A. Hua, Y. S. Yang, Y. N. Zhang, etc. Three-dimensional finite element analysis of to spinning[J]. Journal of Materials Processing Technology,2005.(168):68-74
[33]张芝亭,冯志猛.大直径中等厚度封头热旋压成形工艺[J].压力容器,1998.15(6)53
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