筒形件强力旋压过程的有限元数值模拟
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摘要
现代旋压技术是广泛应用于航空、航天、军工等金属精密加工技术领域的一种先进塑性成形工艺，强力旋压作为旋压技术的一个重要组成部分，它在制造精度高、长径比大的薄壁筒形零件加工中，显出了独特的优越性，已成为成形小批量、多品种回转型薄壁壳体零件的重要加工方法。长期以来对强力旋压过程的研究还是建立在试验的基础上，对强力旋压的过程控制还依赖于经验值，对于强力旋压过程中缺陷产生的原因也不能很好地解释。为了系统地研究强力旋压的成形规律，本文采用计算机数值模拟的方法对其进行了研究，主要研究成果和新见解如下：
针对强力旋压的过程和电接触原理相似这一特点，提出了一种新的强力旋压加热方式和其实现原理，并建立了相关的理论分析模型。此加热方法相对于其它方法，具有加热迅速和集中等特点，能节约能源和减少环境的污染。
通过对强力旋压过程的分析，有效地处理了旋轮加载和边界约束等条件，分别采用solid单元和shell单元对坯料和芯模、旋轮进行了模型的离散化，建立了符合实际的三维有限元模型。
用弹塑性有限元法对强力旋压过程进行了模拟，获得了强力旋压稳定状态下应力应变的分布规律，解释了强力旋压的变形机理和隆起、扩径、缩径、母线偏转等缺陷产生的原因。
对不同工艺参数下的强力旋压过程进行了模拟，获得了成形角、减薄率、进给比等工艺参数对等效应力和旋压力的影响规律，为旋压工艺参数的选择和优化提供了依据。
对带加强筋的筒形件强力旋压过程进行了模拟，得到其应力应力的分布规律，通过和不带加强筋的筒形件强力旋压过程的比较，结果表明其应力应变分布规律相似，变形机理相同。
Modern spinning technology is an advanced plastic forming process and widely used in the field of precise processing technology of aerospace and military industry. Power spinning, one important part of spinning, has unique advantage when the thin wall tube of high precision, large slenderness ratio is made. It is became an important shaping method for flexible manufacturing of small-lot rotary thin-wall parts. For long the study of power spinning process was based on industrial experience. The reason of flaw produced in power spinning processing is not explained well. To study the forming law of power spinning, in this dissertation the power spinning was investigated by computer numerical simulation. A brief introduction of the project and the main results are as following:
A new heating method is presented based on similar characteristic between the process of spinning and electrical contact and the model of academic analysis is built. This heating method has the characteristics of rapid heating and concentration and it can reduce the resource consumption and environment pollution.
Based on analysis of the power spinning process of one roller, the boundary condition and the determination of load type are disposed effectively. The solid and shell element is used in discreting the blank and mandrel, roller respectively. The mechanical model, which fit well with the real process of tube spinning, is established.
The process of tube spinning is simulated by 3D elasto-plastic FEM. The distribution of stress and strain is obtained. The results can well interpret these appearances of enlarging and reducing of diameter as well as deflection of generating line and build up etc.
The tube spinning of deferent technological parameter is simulated. The influence law of various parameters on spinning force and equivalent stress is obtained and it provides theoretical evidence for determining the rational parameters and improving the dimensional accuracy of products.
The process spinning of tube with longitudinal inner ribs is simulated. The distribution of stress and strain is obtained and compared with that of the process spinning of tube with no longitudinal inner ribs. The conclusion that they have the kindred distribution of stress and strain and the same deformation mechanism, is
obtained.
针对强力旋压的过程和电接触原理相似这一特点，提出了一种新的强力旋压加热方式和其实现原理，并建立了相关的理论分析模型。此加热方法相对于其它方法，具有加热迅速和集中等特点，能节约能源和减少环境的污染。
通过对强力旋压过程的分析，有效地处理了旋轮加载和边界约束等条件，分别采用solid单元和shell单元对坯料和芯模、旋轮进行了模型的离散化，建立了符合实际的三维有限元模型。
用弹塑性有限元法对强力旋压过程进行了模拟，获得了强力旋压稳定状态下应力应变的分布规律，解释了强力旋压的变形机理和隆起、扩径、缩径、母线偏转等缺陷产生的原因。
对不同工艺参数下的强力旋压过程进行了模拟，获得了成形角、减薄率、进给比等工艺参数对等效应力和旋压力的影响规律，为旋压工艺参数的选择和优化提供了依据。
对带加强筋的筒形件强力旋压过程进行了模拟，得到其应力应力的分布规律，通过和不带加强筋的筒形件强力旋压过程的比较，结果表明其应力应变分布规律相似，变形机理相同。
Modern spinning technology is an advanced plastic forming process and widely used in the field of precise processing technology of aerospace and military industry. Power spinning, one important part of spinning, has unique advantage when the thin wall tube of high precision, large slenderness ratio is made. It is became an important shaping method for flexible manufacturing of small-lot rotary thin-wall parts. For long the study of power spinning process was based on industrial experience. The reason of flaw produced in power spinning processing is not explained well. To study the forming law of power spinning, in this dissertation the power spinning was investigated by computer numerical simulation. A brief introduction of the project and the main results are as following:
A new heating method is presented based on similar characteristic between the process of spinning and electrical contact and the model of academic analysis is built. This heating method has the characteristics of rapid heating and concentration and it can reduce the resource consumption and environment pollution.
Based on analysis of the power spinning process of one roller, the boundary condition and the determination of load type are disposed effectively. The solid and shell element is used in discreting the blank and mandrel, roller respectively. The mechanical model, which fit well with the real process of tube spinning, is established.
The process of tube spinning is simulated by 3D elasto-plastic FEM. The distribution of stress and strain is obtained. The results can well interpret these appearances of enlarging and reducing of diameter as well as deflection of generating line and build up etc.
The tube spinning of deferent technological parameter is simulated. The influence law of various parameters on spinning force and equivalent stress is obtained and it provides theoretical evidence for determining the rational parameters and improving the dimensional accuracy of products.
The process spinning of tube with longitudinal inner ribs is simulated. The distribution of stress and strain is obtained and compared with that of the process spinning of tube with no longitudinal inner ribs. The conclusion that they have the kindred distribution of stress and strain and the same deformation mechanism, is
obtained.
引文
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[2] 张士宏，许沂．塑性加工技术的新近展．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．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．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)．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．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．中国机械工程，2000，11(1-2)：65-70
[9] C.C. Wong, T. A. Dean and J. Lin. A review of Spinning, Shear Forming and Flow Forming Processes, International Journal of Machine Tools and Manufacture, 2003, 43(14): 1419-1435
[10] 王成和，刘克璋等．旋压技术．机械工业出版社，1986
[11] 陈适先等．强力旋压及其应用．国防工业出版社，1966
[12] 日本塑性加工学会．旋压成形技术．机械工业出版社，1988
[13] 陈适先，贾文铎等．强力旋压工艺与设备．国防工业出版社，1986
[14] 刘建华，杨合，李玉强．旋压技术基本原理的研究现状与发展趋势．重型机械，2002，(3)：1-4
[15] 赵云豪，张顺福．国內旋压技术发展的回顾与展望．第七届全国旋压学术年会论文集，1999：419-421
[16] Rajnish Prakash, R.P.Singhal. Shear Spinning Technology for Manufacture of Long Thin Wall Tubes of Small Bore. 1995, 54:186-192
[17] 韩冬，陈辉．温度梯度对TA1旋压圆筒质量的影响．固体火箭技术，1999，22(1)：72-74
[18] 王振生．变薄旋压加热工艺试验研究．锻压技术，2002，(1)：39-41
[19] 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
[20] 周照耀，阮峰，吕炎等．筒形件反旋的三维刚塑性有限元分析．锻压技术，1997，(1)：29-33
[21] 赵宪明，吴迪等．筒形件强力旋压变形机理的有限元分析．塑性工程学报，1998，5(3)：61-65
[22] 许沂，李萍等．筒形件正旋旋压力有限元计算分析．锻压机械，1999，(3)：11-13
[23] 许沂，李萍等．筒形件反旋旋压力模拟分析．热加工艺，1999，(3)：26-27
[24] Eamonn Quigkiy, John Monaghan. Metal Forming: an Analysis of Spinning Processes. Journal of Materials Processing Technology, 2000, 103(1): 114-119
[25] 程礼椿．电接触理论及应用．机械工业出版社，1985
[26] (苏)亚罗舍维奇．电接触强化．国防工业出版社，1986
[27] 邢淑议，王世洪．铝合金和钛合金．机械工业出版社，1987
[28] 程礼椿．论接触电阻模型与应用问题．高压电器，1993，(2)：34-40
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