变薄旋压工艺数值模拟及实验分析
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摘要
旋压技术已经广泛应用于回转体工件的加工,例如车轮、灯罩、导弹外壳等。在生产过程中坯料易产生拉裂、起皮、鼓包等工艺缺陷,因此对旋压成形机理和变形规律的研究成为亟待解决的关键问题。
本文建立了锥形件和车轮轮辐旋压成形的有限元模型,并采用ANSYS/LS-DYNA软件进行了数值模拟,结合实验研究了旋压变形机理,分析了工艺参数对成形过程和工件质量的影响。
本文首先分析了旋压生产的工艺特点,基于塑性变形理论及有限元技术,采用ANSYS/LS-DYNA建立了旋压成形有限元模型。在建模过程中对比了体网格和面网格的优劣,利用旋轮轴、数组和坐标运算,解决了接触、旋轮运动轨迹描述等多个关键问题,并对运算过程中易出现的数据中断问题进行了调整。分别采取调整单元类型、增大变形体的刚度、增大部件之间的间隙等措施,改进了模拟中存在的负体积、穿透、网格畸变严重等问题。有限元模型的建立为之后对成形规律和工艺参数的研究奠定了基础。
基于有限元模型,分别分析了锥形件和车轮轮辐旋压成形的变形特征和应力应变规律,并分析了工艺参数对旋压成形的影响。在锥形件旋压成形过程中,分析了应力应变对坯料中心孔及整体成形精度的影响、坯料内外表面应变差异；同时也分析了进给率、偏离率等工艺参数对应力应变及工件成形质量的影响,解释了起皮、拉裂等缺陷的产生原因。在车轮轮辐成形过程中,获得了应力应变的分布,分析了旋轮圆角半径、旋轮安装角和主轴转速等工艺参数对应力应变、壁厚及壁厚减薄率的影响,预测了过度减薄和开裂等缺陷易产生的位置。
最后根据模拟结果进行了实验验证,利用优化后的工艺参数,得到了质量良好的工件。
Spinning technology has been used widely in the machining process of axially symmetrical workpiece, such as wheels, lampshades, missile shells, etc. Some process defects easily appeared in the production, such as cracking, peeling, bulging. So the research of forming mechanism and deformation regularities become to a key problem urgently to be solved.
The finite element model of the spinning process for cone parts and wheel spokes were established. ANSYS/LS-DYNA was used to carry out numerical simulation. Combined with the experiment, spinning deformation mechanism was researched. The influence of process parameters to the forming process and workpiece quality was analyzed.
Spinning process features was analyzed firstly. Based on plastic deformation theory and finite element technology, finite element model of spinning forming was established using ANSYS/LS-DYNA. Volume mesh and area mesh were compared in modeling. Some key problems, such as contact and path of the roller, were solved by using axle of the roller, array and coordinate operations. Data interruption in computing was adjusted. Some measures, such as adjusting element type, increasing the stiffness of deformable objects and gap of parts, were adopted to improve problems like negative volume, penetration and mesh distortion. The establishment of the finite element model laid the foundation for the research of deformation regularities and process parameters.
The deformation features and regularities of stress-strain distribution of cone parts and wheel spokes were analyzed based on the finite element model. The influence of process parameters to spinning forming was analyzed. In cone part spinning, the influence of stress and strain to center hole of blank and forming accuracy was analyzed. The strain differences of internal and external surface were analyzed. The influence of process parameters, such as roller feed rate and deviation rate to stress-strain and forming quality, was analyzed. The reasons of defect, such as crack and peeling, were explained. In spoke spinning, the regularities of stress-strain distribution were obtained. The influence of process parameters, such as roller fillet radius, setting angle and spindle speed to stress-strain, wall thickness and wall thickness reduction was analyzed. The location of excessive reduction and cracking was forecasted.
Some experiments were carried out according to the simulation results. Good quality workpiece was obtained using the optimized parameters.
本文建立了锥形件和车轮轮辐旋压成形的有限元模型,并采用ANSYS/LS-DYNA软件进行了数值模拟,结合实验研究了旋压变形机理,分析了工艺参数对成形过程和工件质量的影响。
本文首先分析了旋压生产的工艺特点,基于塑性变形理论及有限元技术,采用ANSYS/LS-DYNA建立了旋压成形有限元模型。在建模过程中对比了体网格和面网格的优劣,利用旋轮轴、数组和坐标运算,解决了接触、旋轮运动轨迹描述等多个关键问题,并对运算过程中易出现的数据中断问题进行了调整。分别采取调整单元类型、增大变形体的刚度、增大部件之间的间隙等措施,改进了模拟中存在的负体积、穿透、网格畸变严重等问题。有限元模型的建立为之后对成形规律和工艺参数的研究奠定了基础。
基于有限元模型,分别分析了锥形件和车轮轮辐旋压成形的变形特征和应力应变规律,并分析了工艺参数对旋压成形的影响。在锥形件旋压成形过程中,分析了应力应变对坯料中心孔及整体成形精度的影响、坯料内外表面应变差异；同时也分析了进给率、偏离率等工艺参数对应力应变及工件成形质量的影响,解释了起皮、拉裂等缺陷的产生原因。在车轮轮辐成形过程中,获得了应力应变的分布,分析了旋轮圆角半径、旋轮安装角和主轴转速等工艺参数对应力应变、壁厚及壁厚减薄率的影响,预测了过度减薄和开裂等缺陷易产生的位置。
最后根据模拟结果进行了实验验证,利用优化后的工艺参数,得到了质量良好的工件。
Spinning technology has been used widely in the machining process of axially symmetrical workpiece, such as wheels, lampshades, missile shells, etc. Some process defects easily appeared in the production, such as cracking, peeling, bulging. So the research of forming mechanism and deformation regularities become to a key problem urgently to be solved.
The finite element model of the spinning process for cone parts and wheel spokes were established. ANSYS/LS-DYNA was used to carry out numerical simulation. Combined with the experiment, spinning deformation mechanism was researched. The influence of process parameters to the forming process and workpiece quality was analyzed.
Spinning process features was analyzed firstly. Based on plastic deformation theory and finite element technology, finite element model of spinning forming was established using ANSYS/LS-DYNA. Volume mesh and area mesh were compared in modeling. Some key problems, such as contact and path of the roller, were solved by using axle of the roller, array and coordinate operations. Data interruption in computing was adjusted. Some measures, such as adjusting element type, increasing the stiffness of deformable objects and gap of parts, were adopted to improve problems like negative volume, penetration and mesh distortion. The establishment of the finite element model laid the foundation for the research of deformation regularities and process parameters.
The deformation features and regularities of stress-strain distribution of cone parts and wheel spokes were analyzed based on the finite element model. The influence of process parameters to spinning forming was analyzed. In cone part spinning, the influence of stress and strain to center hole of blank and forming accuracy was analyzed. The strain differences of internal and external surface were analyzed. The influence of process parameters, such as roller feed rate and deviation rate to stress-strain and forming quality, was analyzed. The reasons of defect, such as crack and peeling, were explained. In spoke spinning, the regularities of stress-strain distribution were obtained. The influence of process parameters, such as roller fillet radius, setting angle and spindle speed to stress-strain, wall thickness and wall thickness reduction was analyzed. The location of excessive reduction and cracking was forecasted.
Some experiments were carried out according to the simulation results. Good quality workpiece was obtained using the optimized parameters.
引文
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2.张士宏,许沂.塑性加工技术的新进展[J].锻压技术,2001,(6)：85-87.
3.张士宏.塑性加工技术的科学化与中国塑性加工技术的发展世界[J].科技研究与发展,2001,23(5)：5-11.
4.洪慎章.塑性成形技术的现状及发展趋势[J].模具技术,2003,(1)：54-56.
5.周贤宾.塑性加工技术的发展——更精、更省、更净[J].中国机械工程,2003,14(1)：85-90.
6.赵军,马瑞.板材成形新技术及其发展趋势(Ⅱ)[J].金属成形工艺,2003,21(2)：1-9.
7.董湘怀,郑莹,兰箭,等.金属塑性成形计算机模拟的若干进展[J].金属成形工艺,2000,18(1)：1-4.
8.宋玉泉.连续局部塑性成形的发展前景[J].中国机械工程,2000,11(1-2)：65-70.
9.赵云豪,李彦利.旋压技术与应用[M].北京：机械工业出版社,2008：1-8.
10. Kalpakcioglu, A study of shear spinnability of metals[J]. Trans, AS ME, Journal of Engineer for Industry.1961,83:478～484.
11. Ayama M., Murota T.Theoretical study of shear spinning[J]. Bulletin of N JSME.1965, 8(31):460～467.
12.李克智,吕炎.筒形件正旋时位移分布规律的研究[J].塑性工程学报.1996,3(4)：61-63.
13.李超玲.筒形件强力旋压过程的有限元数值模拟[D].西北工业大学硕士学位论文,2003：1-2.
14.陈适先,贾文铎.强力旋压工艺与设备[M].北京：国防工业出版社,1986.
15.徐恒秋,樊桂森,张锐,等.旋压设备及工艺技术的应用与发展[J].新技术新工艺,2007,(2)：6-8.
16.陈适先.我国旋压事业的发展与展望[J].锻压与冲压,2005(10)：20-25.
17.陈适先,等.锻压手册[M].北京：机械工业出版社,2002：505-565.
18. Da-Chang Kang, Xi-Cheng Gao, Xian-Feng Meng et al. Study of the deformation mode of comventional spinning of plates[J]. Journal of Materials Processing Technology,1999, 91(1-3):226～230.
19. J.H.Liu, H.Yang, Y.Q.Li. A study of the stess and strain distributions of first-pass convertional spinning under different roller-traces[J]. Journal of Materials Processing Technology,2002,129(1-3):326～329.
20. S.-C.Chang, C.-A.Huang, S.-Y.Yu et al. Tube spinnability of AA 2024 and 7075 aluminum alloys[J]. Journal of Materials Processing Technology,1998,80-81:676～682.
21.吕听宇,王本贤,许沂,等.LF6合金锻坯旋压成形小锥度铝筒实验研究[J].锻压装备与制造技术,2004,(5)：52-54.
22. Rajnish Prakash, R.P.Singhal. Shear spinning technology for manufacture of long thin wall tubes of small bore[J]. Journal of Materials Processing Technology,1995,54(1-4): 186～192.
23.叶山益次郎.回转塑性加工学[M].近代编辑社：1978.
24. E.Quigley, J.Monaghan. Enhanced finite element models of metal spinning[J]. Journal of Materials Processing Technology,2002 (121):43-49.
25. E.Quigley, J.Monaghan. The finite modeling of conventional spinning using multi-domain models[J]. Journal of Material Processing Technology,2002,124(3):360-365.
26. Jae-Woo Park, Young-Ho Kim, Won-Byong Bae. Analysis of tube-spinning processes by the upper-bound stream-function method[J]. Journal of Materials Processing Technology 66(1997):195-203.
27. O.Music, J.M.Allwood, K.Kawai. A review of the mechanics of metal spinning[J]. Journal of Materials Processing Technology,2010(210):3-23.
28. Akkus N, Kawahara M. An experimental and analytical study on dome forming of seamless Al tube by spinning process[J]. Journal of Material Processing Technology,2006, 173(2):145-150.
29. M. Zhan, H. Yang, J. H. Zhang, et al.3D FEM analysis of influence of roller feed rate on forming force and quality of cone spinning[J]. Materials Processing Technology, 187-188(2007)486-491.
30.詹梅,李虎,杨合,等.大型复杂薄壁壳体多道次旋压过程中的壁厚变化[J].塑性工程学报2008,15(2)：115-121.
31.徐银丽.异型薄壁壳体强旋成形机理及规律的三维有限元分析[D].西北工业大学硕士学位论文,2006.
32.黄亮,杨合,詹梅.分形旋压成形技术研究进展[J].材料科学与工艺,2008,16(4)：476-480.
33.张庆玲.铝合金轮毂强力旋压数值模拟技术研究[J].农业装备与车辆工程,2008,8：31-33.
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