薄壁曲母线形件旋压成形的数值模拟及工艺研究
|
摘要
薄壁曲母线形件是广泛用于航空、航天和兵器工业中的一类零件和中间道次旋压件,探讨薄壁曲母线形件的旋压成形机理对于研究其成形规律与成形精度具有很重要的意义。本文建立了薄壁曲母线形件旋压过程的三维有限元模型,研究了曲母线形件旋压成形机理和主要工艺参数对其成形过程的影响规律。
主要内容如下:
在一些假设和简化基础上建立了薄壁曲母线形件旋压成形的有限元模型,并对其成形过程进行了模拟。通过对模拟结果的分析,得到了在曲母线形件拉深旋压成形过程中应力应变的分布及变化规律,从而探讨了曲母线形件旋压过程的成型机理及成形规律。
研究各种工艺参数(如旋轮直径、进给比、主轴转速和坯料倾斜角等)对薄壁曲母线形件旋压成形过程的影响。通过对比不同工艺参数下的模拟结果,得到了不同工艺参数对旋压成形质量、等效应力与等效应变、旋压力这些旋压件性能指标的影响规律,为工艺参数的选择提供了依据,并在此基础上确定了一组合理的工艺参数值。通过对模拟结果的分析,文中还探讨了可能产生的缺陷及其预防措施,从而为该类零件的旋压成形提供了一定的参考。
The parts with the shape of thin-wall and curvilinear generatrix are a kind of parts and pony-roughing pass spun parts which are widely used in the industry of aviation, aerospace and weapons. It will be great significant to discuss the spinning forming theory of this kind of parts for the research of their forming discipline and forming precision. A three-dimensional finite element model of the parts with the shape of thin-wall and curvilinear generatrix during the forming process has been established in this text, and spinning forming theory of this kind of parts besides the law of how the main technological parameters affecting their forming process have been researched. The main content is as follow:
A finite element model for the process of forming this kind of spun parts has been established. The forming process has been simulated. By the analysis of the simulated results, the distribution and alteration law of stress and strain about the parts with the shape of thin-wall and curvilinear generatrix during the deep drawing spinning process is gained, thus spinning forming theory of the parts with the shape of thin-wall and curvilinear generatrix during the spinning process can be discussed in a certain extent.
Effect of the minor technological parameters (such as temperature, equipment characteristic and material property, etc.) is neglected in the text and only the effect of the main technological parameters (such as the diameter of the wheel, feed speed of wheel, rotate speed of the spindle and dip angle of the work piece) which affect the spin forming process has been researched. By comparing the simulation result of different technological parameters, the law of how the different technological parameters affect the performance index of the spun parts has been gained, and the parameters which were mentioned above include forming quality,the equivalent stress and the equivalent strain, the spinning force. It provides reference for selecting the technological parameters, and reasonable technological parameters are selected basing on it. By the analysis of the simulation result, the possible defect and the preventive action have been discussed, and the reference is provided for spin forming process of this kind of work piece.
主要内容如下:
在一些假设和简化基础上建立了薄壁曲母线形件旋压成形的有限元模型,并对其成形过程进行了模拟。通过对模拟结果的分析,得到了在曲母线形件拉深旋压成形过程中应力应变的分布及变化规律,从而探讨了曲母线形件旋压过程的成型机理及成形规律。
研究各种工艺参数(如旋轮直径、进给比、主轴转速和坯料倾斜角等)对薄壁曲母线形件旋压成形过程的影响。通过对比不同工艺参数下的模拟结果,得到了不同工艺参数对旋压成形质量、等效应力与等效应变、旋压力这些旋压件性能指标的影响规律,为工艺参数的选择提供了依据,并在此基础上确定了一组合理的工艺参数值。通过对模拟结果的分析,文中还探讨了可能产生的缺陷及其预防措施,从而为该类零件的旋压成形提供了一定的参考。
The parts with the shape of thin-wall and curvilinear generatrix are a kind of parts and pony-roughing pass spun parts which are widely used in the industry of aviation, aerospace and weapons. It will be great significant to discuss the spinning forming theory of this kind of parts for the research of their forming discipline and forming precision. A three-dimensional finite element model of the parts with the shape of thin-wall and curvilinear generatrix during the forming process has been established in this text, and spinning forming theory of this kind of parts besides the law of how the main technological parameters affecting their forming process have been researched. The main content is as follow:
A finite element model for the process of forming this kind of spun parts has been established. The forming process has been simulated. By the analysis of the simulated results, the distribution and alteration law of stress and strain about the parts with the shape of thin-wall and curvilinear generatrix during the deep drawing spinning process is gained, thus spinning forming theory of the parts with the shape of thin-wall and curvilinear generatrix during the spinning process can be discussed in a certain extent.
Effect of the minor technological parameters (such as temperature, equipment characteristic and material property, etc.) is neglected in the text and only the effect of the main technological parameters (such as the diameter of the wheel, feed speed of wheel, rotate speed of the spindle and dip angle of the work piece) which affect the spin forming process has been researched. By comparing the simulation result of different technological parameters, the law of how the different technological parameters affect the performance index of the spun parts has been gained, and the parameters which were mentioned above include forming quality,the equivalent stress and the equivalent strain, the spinning force. It provides reference for selecting the technological parameters, and reasonable technological parameters are selected basing on it. By the analysis of the simulation result, the possible defect and the preventive action have been discussed, and the reference is provided for spin forming process of this kind of work piece.
引文
[1]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[M] .冶金工业出版社2003,1.
[2]宋玉泉.连续局部塑性成形的发展前景[J].中国机械工程, 2000,(1-2):65~67
[3]徐洪烈.强力旋压技术[M].北京:国防工业出版社, 1984
[4]侯红亮,余肖放,王耀奇.国内旋压设备及其相关技术的发展与现状[J].锻压装备与制造技术, 2009,(4):16~19
[5]张涛.旋压成形工艺[M].北京:化学工业出版社, 2009:1~2
[6]赵云豪.旋压技术现状[J].锻压技术, 2005,(5):95~100
[7]李继贞,李志强,余肖放.我国旋压技术的现状与发展[J].锻压技术,2005,(增刊):17~20
[8]杨俊,马世成等.旋压技术发展与应用[J]. Defense Manufacturing Technology, 2009,03,(01):65~68
[9]马菽聪.铝合金拉深旋压成形规律的研究[D]. [燕山大学硕士学位论文],2008
[10]夏琴香,杨明辉等.工艺参数对杯形内啮合齿轮旋压成形影响的数值模拟研究[J].塑性工程学报, 2006,8(4):1~5
[11]吕宏军,余汪洋,王琪等. TC4钛合金旋压有限元数值模拟分析[J].天津工业大学学报,2007,26(6):59~65
[12]徐文臣,张恒大等. TC4钛合金轮圈热旋成形技术研究[J].材料科学与工艺, 2008,2(1):14~18
[13]刘粉妮.筒形变薄旋压加工有限元分析[D]. [四川大学硕士毕业论文], 2006
[14]李超龄.筒形件强力旋压过程的有限元数值模拟[D]. [西北工业大学硕士毕业论文], 2008
[15] G. Sebastinani, A. Brosius, R. Ewers, M. Kleiner, C. Klimmek, Numerical investigation on Dynamic effects during sheet metal spinning by explicit finite-element-analysis[J]. Journal of Materials Processing Technology, 2006,(177):401~403
[16] Ken-ichiro Mori, Takayuki Nonaka. Simplified Three-Dimensional Finite Element Simulation of Shear Spinning Process Based on Axisymmetric Modeling[J]. Journal of Manufacturing Process, 2005,(Vol 7/No.1):51~56
[17] M. EL-Khabeery, M. Fattouh. On the conventional Simple Spinning of Cylindrical Aluminum Cups[J]. International Journal of Machine Tools & Manufacture, 1991,(2):203~219
[18] John C.Slattery, Sangheon Lee. Analysis of melt spinning[J]. Non-Newtonian Fluid Mech, 2000,(89):273~286
[19] Wong C C, Dean T A, Lin J. A review of spinning, shear forming and flow forming processes [J]. International Journal of Machine Tools & Manufacture, 2003,(43):1419~1435
[20] S.-C.Chang, C.-A.Huang, S.-Y.Yu, etc. Tube spinnability of AA 2024 and 7075 aluminum alloys[J]. Journal of Materials Processing Technology, 1998,(81): 676~682
[21] J.S. Park. S. M. Hwang. Automatic Remeshing in Finite Element Simulation of Metal Forming Processing by Guide Gride Method[J]. Journal of Materials Processing Technology, 1991,(27):73~89
[22] P. P. Crimmins. Spinning of Refractory Alloys[J]. Metal Progress, 1994,(1):36~39
[23] Eamonn Quigley, John Monaghan. Metal Forming: Analysis of Spinning Process[J]. J.Mater. Process Technol., 2000,(103):114~119
[24]徐银丽.异型薄壁壳体强力旋压成形机理及规律的三维有限元分析[D]. [西北工业大学硕士毕业论文], 2006
[25]毛柏平,王振生. 6061合金特种筒件旋压工艺及组织性能研究[J].轻合金加工技术, 2008,(6):38~41
[26]李灵凤,孟艳梅. U型密封圈旋压过程的有限元力学模型建立[J].机械工程师, 2005,(11):55~56
[27]王艳红.车轮轮毂旋压成形技术研究[D]. [燕山大学硕士毕业论文], 2008
[28]陈一鸣,周漪清.超长圆锥管无芯模旋拉过程的三维数值模拟[J].锻压技术, 2005, (5): 39~42
[29]陈辉.复杂曲面薄壁件精密旋压成形技术研究[D]. [四川大学工程硕士毕业论文], 2008
[30]王浩然.模环旋压成形过程的数值模拟与工艺优化[D]. [大连理工大学硕士毕业论文], 2008
[31]张涛,林刚.旋压缩口过程的三维有限元数值模拟[J].锻压技术, 2001(5):26~28
[32]马明娟,詹梅等.异型薄壁壳体强力旋压三维有限元模型的建立[J].中国机械工程, 2006,(第17卷增刊):92~95
[33]郝继东,刑照斌等.锥形件三维变薄旋压数值模拟[J].锻压技术, 2010,(6):80~83
[34]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[J] .锻压技术, 1997, (4):23~25
[35]李灵凤.变壁厚锥形件强力旋压过程有限元力学模型的建立[J].特种成形, 2006,(1):64~66
[36]李亚非,陈辉.薄壁铝合金锥形件旋压成形过程的缺陷分析[J].锻压技术,2008,(33): 56~59
[37]刘陶,龙思远.基于DEFORM-3D的铝合金筒形件旋压成形过程数值模拟[J].特种铸造及有色合金, 2010,(30):508~510
[38]高西成,陈宇,康达昌.锥形件无芯模旋压的静态有限元分析[J].哈尔滨工业大学学报, 2003,(35):253~256
[39]江树勇,孙金凤,赵立红等.纵向内筋薄壁筒反向滚珠旋压有限元分析[J].锻压技术, 2009, (34):35~38
[40]张小光,钟志平,张建荣等.旋压技术在等强度钢制车轮制造中的应用[J].锻压技术, 2009, (34):24~26
[41]张涛,刘智冲,马世成.旋压成形带内筋筒形件的工艺研究及数值模拟[J].机械工程学报, 2007,(43): 109~118
[42]夏琴香,邝卫华,阮锋.筒形件三旋轮缩径旋压过程的数值模拟[J].锻压技术, 2005,(1) : 44~46
[43]何艳斌,程秀全,夏琴香.成形工艺参数对三维非轴对称零件旋压成形质量的影响[J].特种成形, 2006,(3): 79~81
[44]龚曙光. ANSYS基础应用及范例解析[M].北京:机械工业出版社, 2003:29~444
[45]何涛,杨竞,金鑫. ANSYS 10.0/LS-DYNA非线性有限元分析实例指导教程[M],北京:机械工业出版社, 2007,1:5-14
[46]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西安:西北工业大学出版社,2001:1~151
[47]白金泽. LS-DYNA3D理论基础与实例分析[M].北京:科学出版社, 2005:1~4
[48] E .Quigley, J. Monaghan . Enhanced finite element models of metal spinning [J]. Journal of Materials Processing Technology, 2002,(121):43~49
[49]高西成,康达昌.薄壁筒收口旋压过程的数值模拟[J] .塑性工程学报, 1999,(4):54~57
[50]夏琴香,陈家华,梁佰祥.基于数值模拟的无芯模旋压收口工艺[J].华南理工大学学报(自然科学版), 2006,2(2):1~7
[51]程秀全,陈家华,夏琴香等.无芯模缩径旋压力的有限元数值模拟及实验研究[J].塑性工程学报,2007,(10):38~42
[52]贾英辉.管件端部收口热旋压时的数值模拟及工艺参数的确定[D]. [辽宁工程技术大学硕士毕业论文], 2008
[53]李启军,吕宏军等.高深径比TC4钛合金筒形件普旋成型有限元数值模拟[J].宇航材料工艺, 2006(增刊I):88~92
[54]张恒大.月球车钛合金轮圈的热旋压成形工艺研究[D]. [哈尔滨工业大学硕士毕业论文], 2006
[55]苏畅.厚壁封头无胎温旋压成形的数值模拟[D] . [燕山大学硕士毕业论文], 2001
[56]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[J] .塑性工程学报, 1994, (3):37~42
[57]滕焕波. AZ31镁合金筒形件旋压技术研究[D]. [中北大学硕士毕业论文], 2007
[58]李超玲.筒形件强力旋压过程的有限元数值模拟[D]. [西北工业大学硕士毕业论文],2004
[59]孟艳梅.曲母线形件复合旋压成形的数值模拟及工艺分析[D]. [燕山大学硕士毕业论文], 2005
[60]马明娟.大型复杂薄壁壳体多道次旋压成形机理及规律的三维有限元分析[D]. [西北工业大学硕士毕业论文], 2007
[61]韩志仁,陶华,刘黎明.筒形件强力旋压有限元模拟研究[J].机械设计与制造,2006,(11): 137~139
[62]韩志仁,陶华,刘黎明.筒形件强力内旋压有限元模拟[J].机械科学与技术, 2004,(1):63~65
[63]王大力,马世成.旋压工艺力、扭矩和功率的实验分析研究[J].煤矿机械, 2004,(5):30~32
[64]王华侨,张如平,翟永卉等.铝合金旋压塑性成形的有限元模拟分析及其应用[J].航空制造技术,2006(11):80~84
[2]宋玉泉.连续局部塑性成形的发展前景[J].中国机械工程, 2000,(1-2):65~67
[3]徐洪烈.强力旋压技术[M].北京:国防工业出版社, 1984
[4]侯红亮,余肖放,王耀奇.国内旋压设备及其相关技术的发展与现状[J].锻压装备与制造技术, 2009,(4):16~19
[5]张涛.旋压成形工艺[M].北京:化学工业出版社, 2009:1~2
[6]赵云豪.旋压技术现状[J].锻压技术, 2005,(5):95~100
[7]李继贞,李志强,余肖放.我国旋压技术的现状与发展[J].锻压技术,2005,(增刊):17~20
[8]杨俊,马世成等.旋压技术发展与应用[J]. Defense Manufacturing Technology, 2009,03,(01):65~68
[9]马菽聪.铝合金拉深旋压成形规律的研究[D]. [燕山大学硕士学位论文],2008
[10]夏琴香,杨明辉等.工艺参数对杯形内啮合齿轮旋压成形影响的数值模拟研究[J].塑性工程学报, 2006,8(4):1~5
[11]吕宏军,余汪洋,王琪等. TC4钛合金旋压有限元数值模拟分析[J].天津工业大学学报,2007,26(6):59~65
[12]徐文臣,张恒大等. TC4钛合金轮圈热旋成形技术研究[J].材料科学与工艺, 2008,2(1):14~18
[13]刘粉妮.筒形变薄旋压加工有限元分析[D]. [四川大学硕士毕业论文], 2006
[14]李超龄.筒形件强力旋压过程的有限元数值模拟[D]. [西北工业大学硕士毕业论文], 2008
[15] G. Sebastinani, A. Brosius, R. Ewers, M. Kleiner, C. Klimmek, Numerical investigation on Dynamic effects during sheet metal spinning by explicit finite-element-analysis[J]. Journal of Materials Processing Technology, 2006,(177):401~403
[16] Ken-ichiro Mori, Takayuki Nonaka. Simplified Three-Dimensional Finite Element Simulation of Shear Spinning Process Based on Axisymmetric Modeling[J]. Journal of Manufacturing Process, 2005,(Vol 7/No.1):51~56
[17] M. EL-Khabeery, M. Fattouh. On the conventional Simple Spinning of Cylindrical Aluminum Cups[J]. International Journal of Machine Tools & Manufacture, 1991,(2):203~219
[18] John C.Slattery, Sangheon Lee. Analysis of melt spinning[J]. Non-Newtonian Fluid Mech, 2000,(89):273~286
[19] Wong C C, Dean T A, Lin J. A review of spinning, shear forming and flow forming processes [J]. International Journal of Machine Tools & Manufacture, 2003,(43):1419~1435
[20] S.-C.Chang, C.-A.Huang, S.-Y.Yu, etc. Tube spinnability of AA 2024 and 7075 aluminum alloys[J]. Journal of Materials Processing Technology, 1998,(81): 676~682
[21] J.S. Park. S. M. Hwang. Automatic Remeshing in Finite Element Simulation of Metal Forming Processing by Guide Gride Method[J]. Journal of Materials Processing Technology, 1991,(27):73~89
[22] P. P. Crimmins. Spinning of Refractory Alloys[J]. Metal Progress, 1994,(1):36~39
[23] Eamonn Quigley, John Monaghan. Metal Forming: Analysis of Spinning Process[J]. J.Mater. Process Technol., 2000,(103):114~119
[24]徐银丽.异型薄壁壳体强力旋压成形机理及规律的三维有限元分析[D]. [西北工业大学硕士毕业论文], 2006
[25]毛柏平,王振生. 6061合金特种筒件旋压工艺及组织性能研究[J].轻合金加工技术, 2008,(6):38~41
[26]李灵凤,孟艳梅. U型密封圈旋压过程的有限元力学模型建立[J].机械工程师, 2005,(11):55~56
[27]王艳红.车轮轮毂旋压成形技术研究[D]. [燕山大学硕士毕业论文], 2008
[28]陈一鸣,周漪清.超长圆锥管无芯模旋拉过程的三维数值模拟[J].锻压技术, 2005, (5): 39~42
[29]陈辉.复杂曲面薄壁件精密旋压成形技术研究[D]. [四川大学工程硕士毕业论文], 2008
[30]王浩然.模环旋压成形过程的数值模拟与工艺优化[D]. [大连理工大学硕士毕业论文], 2008
[31]张涛,林刚.旋压缩口过程的三维有限元数值模拟[J].锻压技术, 2001(5):26~28
[32]马明娟,詹梅等.异型薄壁壳体强力旋压三维有限元模型的建立[J].中国机械工程, 2006,(第17卷增刊):92~95
[33]郝继东,刑照斌等.锥形件三维变薄旋压数值模拟[J].锻压技术, 2010,(6):80~83
[34]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[J] .锻压技术, 1997, (4):23~25
[35]李灵凤.变壁厚锥形件强力旋压过程有限元力学模型的建立[J].特种成形, 2006,(1):64~66
[36]李亚非,陈辉.薄壁铝合金锥形件旋压成形过程的缺陷分析[J].锻压技术,2008,(33): 56~59
[37]刘陶,龙思远.基于DEFORM-3D的铝合金筒形件旋压成形过程数值模拟[J].特种铸造及有色合金, 2010,(30):508~510
[38]高西成,陈宇,康达昌.锥形件无芯模旋压的静态有限元分析[J].哈尔滨工业大学学报, 2003,(35):253~256
[39]江树勇,孙金凤,赵立红等.纵向内筋薄壁筒反向滚珠旋压有限元分析[J].锻压技术, 2009, (34):35~38
[40]张小光,钟志平,张建荣等.旋压技术在等强度钢制车轮制造中的应用[J].锻压技术, 2009, (34):24~26
[41]张涛,刘智冲,马世成.旋压成形带内筋筒形件的工艺研究及数值模拟[J].机械工程学报, 2007,(43): 109~118
[42]夏琴香,邝卫华,阮锋.筒形件三旋轮缩径旋压过程的数值模拟[J].锻压技术, 2005,(1) : 44~46
[43]何艳斌,程秀全,夏琴香.成形工艺参数对三维非轴对称零件旋压成形质量的影响[J].特种成形, 2006,(3): 79~81
[44]龚曙光. ANSYS基础应用及范例解析[M].北京:机械工业出版社, 2003:29~444
[45]何涛,杨竞,金鑫. ANSYS 10.0/LS-DYNA非线性有限元分析实例指导教程[M],北京:机械工业出版社, 2007,1:5-14
[46]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西安:西北工业大学出版社,2001:1~151
[47]白金泽. LS-DYNA3D理论基础与实例分析[M].北京:科学出版社, 2005:1~4
[48] E .Quigley, J. Monaghan . Enhanced finite element models of metal spinning [J]. Journal of Materials Processing Technology, 2002,(121):43~49
[49]高西成,康达昌.薄壁筒收口旋压过程的数值模拟[J] .塑性工程学报, 1999,(4):54~57
[50]夏琴香,陈家华,梁佰祥.基于数值模拟的无芯模旋压收口工艺[J].华南理工大学学报(自然科学版), 2006,2(2):1~7
[51]程秀全,陈家华,夏琴香等.无芯模缩径旋压力的有限元数值模拟及实验研究[J].塑性工程学报,2007,(10):38~42
[52]贾英辉.管件端部收口热旋压时的数值模拟及工艺参数的确定[D]. [辽宁工程技术大学硕士毕业论文], 2008
[53]李启军,吕宏军等.高深径比TC4钛合金筒形件普旋成型有限元数值模拟[J].宇航材料工艺, 2006(增刊I):88~92
[54]张恒大.月球车钛合金轮圈的热旋压成形工艺研究[D]. [哈尔滨工业大学硕士毕业论文], 2006
[55]苏畅.厚壁封头无胎温旋压成形的数值模拟[D] . [燕山大学硕士毕业论文], 2001
[56]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[J] .塑性工程学报, 1994, (3):37~42
[57]滕焕波. AZ31镁合金筒形件旋压技术研究[D]. [中北大学硕士毕业论文], 2007
[58]李超玲.筒形件强力旋压过程的有限元数值模拟[D]. [西北工业大学硕士毕业论文],2004
[59]孟艳梅.曲母线形件复合旋压成形的数值模拟及工艺分析[D]. [燕山大学硕士毕业论文], 2005
[60]马明娟.大型复杂薄壁壳体多道次旋压成形机理及规律的三维有限元分析[D]. [西北工业大学硕士毕业论文], 2007
[61]韩志仁,陶华,刘黎明.筒形件强力旋压有限元模拟研究[J].机械设计与制造,2006,(11): 137~139
[62]韩志仁,陶华,刘黎明.筒形件强力内旋压有限元模拟[J].机械科学与技术, 2004,(1):63~65
[63]王大力,马世成.旋压工艺力、扭矩和功率的实验分析研究[J].煤矿机械, 2004,(5):30~32
[64]王华侨,张如平,翟永卉等.铝合金旋压塑性成形的有限元模拟分析及其应用[J].航空制造技术,2006(11):80~84