AZ31镁合金筒形件旋压技术研究
摘要
针对目前轿车轮毂制造中存在的问题,本文通过研究AZ31镁合金筒形件旋压工艺中工艺变形参数对旋压过程的影响,为对镁合金轮毂的旋压成形技术进行前期试验。
高精度、高强度的薄壁筒形件在工业生产特别是在航空航天和汽车工业等领域中有着广泛的应用,旋压工艺是获得筒形件的一种有效方法。本文应用MSC/MARC软件对镁合金筒形件的旋压过程进行了弹塑性有限元数值模拟,获得旋压成形阶段不同时期的应力应变分布规律、变形流动规律,初步分析了失稳起皱的产生机理。
数值模拟特别是有限元的应用,为旋压工艺提供了先进的分析方法。有限元法可以对成形整个过程进行模拟,有助于揭示各工艺参数对最终零件质量的影响规律,从而缩短研究周期,降低研究成本,对实验研究提供指导和帮助。
通过对镁合金AZ31不同坯料状态进行组织观察和性能测试,为旋压试验提供了依据。在旋压试验过程中,分析了旋压工艺参数对成形零件质量的影响,提出了控制旋压工艺参数的方案。根据有限元数值模拟,对镁合金筒形件的旋压工艺进行了优化,并根据试验结果,分析了镁合金筒形件旋压过程中缺陷的产生机理,提出了相应的控制措施。
同时,通过对AZ31镁合金旋压时金属流动过程的分析,得出了影响该合金塑性的决定性因素是成形温度和成形速度。然后通过实验对模拟结果进行了验证,结果表明:由于采用了合理的旋压工艺参数,避免了旋压中各种旋压缺陷的产生。通过对成形参数的优化设计,保证了金属的成形性能,达到了预期的目的。
Aimed at the question that the car hub exists at present, have studied the influence of deformation parameters and extrusion technology parameters in the spinning caft of cylindrical workpieces of AZ31 magnesium alloy,as former experiment for magnesium-alloy car hub of spinning technique.
High-precision and high-intension cylindrical workpieces are widely applied in industrial production, such as aeronautics, aerospace and automobile. Spinning is the most effective method in obtaining the cylindrical workpieces. In this dissertation,the MSC/MARC software is applied to carry out the elastic-plastic finite element numerical modeling in the spinning process of the magnesium-alloy cylindrical workpieces to get the stress-strain distribution rule,deforming flowing rule,rule in the different periods of the spinning formation stage,and later preliminarily analyze the mechanism of production of the destabilization,corrugation,and dehiscence.
Numerical simulation,especially,the application of the FEM,has provided the advanced analytical methods of the spinning technique. The FEM is used to simulate the whole formation process,and is helpful to unveil the influential rules of the quality of final parts from the technological parameter,and it is also applied to shorten the research period,decrease the study cost,and provide the guidance and help in the experiments.
It provides the basis for the conventional spinning experiment through the texture observation and performance testing of the different stock conditions of the AZ31 magnesium alloy.In the process of spinning experiment,it has analyzed the influence of spinning technological parameter on the end parts quality,and brought in the scheme of controlling spinning technological parameter. According to the numerical simulation and trial results,it has perfected the spinning technique,analyzed the mechanism of production of the blemish,brought in the relevant controlling measures.
Meanwhile,through metal flowing process analyse in the spinning process of AZ31 magnesium alloy,influencing this decisive factor of plasticity are deformation temperature and speed. And has proved to the result of simulation through the experiment, show as a result:Because the spinning technology has adopted the rational craft parameter experemrnt, have avoided disadvantageous phenomenon in the spinning process. Through the optimization design of the mould and the metal is filled with performance better,has achieved the anticipated goal.
高精度、高强度的薄壁筒形件在工业生产特别是在航空航天和汽车工业等领域中有着广泛的应用,旋压工艺是获得筒形件的一种有效方法。本文应用MSC/MARC软件对镁合金筒形件的旋压过程进行了弹塑性有限元数值模拟,获得旋压成形阶段不同时期的应力应变分布规律、变形流动规律,初步分析了失稳起皱的产生机理。
数值模拟特别是有限元的应用,为旋压工艺提供了先进的分析方法。有限元法可以对成形整个过程进行模拟,有助于揭示各工艺参数对最终零件质量的影响规律,从而缩短研究周期,降低研究成本,对实验研究提供指导和帮助。
通过对镁合金AZ31不同坯料状态进行组织观察和性能测试,为旋压试验提供了依据。在旋压试验过程中,分析了旋压工艺参数对成形零件质量的影响,提出了控制旋压工艺参数的方案。根据有限元数值模拟,对镁合金筒形件的旋压工艺进行了优化,并根据试验结果,分析了镁合金筒形件旋压过程中缺陷的产生机理,提出了相应的控制措施。
同时,通过对AZ31镁合金旋压时金属流动过程的分析,得出了影响该合金塑性的决定性因素是成形温度和成形速度。然后通过实验对模拟结果进行了验证,结果表明:由于采用了合理的旋压工艺参数,避免了旋压中各种旋压缺陷的产生。通过对成形参数的优化设计,保证了金属的成形性能,达到了预期的目的。
Aimed at the question that the car hub exists at present, have studied the influence of deformation parameters and extrusion technology parameters in the spinning caft of cylindrical workpieces of AZ31 magnesium alloy,as former experiment for magnesium-alloy car hub of spinning technique.
High-precision and high-intension cylindrical workpieces are widely applied in industrial production, such as aeronautics, aerospace and automobile. Spinning is the most effective method in obtaining the cylindrical workpieces. In this dissertation,the MSC/MARC software is applied to carry out the elastic-plastic finite element numerical modeling in the spinning process of the magnesium-alloy cylindrical workpieces to get the stress-strain distribution rule,deforming flowing rule,rule in the different periods of the spinning formation stage,and later preliminarily analyze the mechanism of production of the destabilization,corrugation,and dehiscence.
Numerical simulation,especially,the application of the FEM,has provided the advanced analytical methods of the spinning technique. The FEM is used to simulate the whole formation process,and is helpful to unveil the influential rules of the quality of final parts from the technological parameter,and it is also applied to shorten the research period,decrease the study cost,and provide the guidance and help in the experiments.
It provides the basis for the conventional spinning experiment through the texture observation and performance testing of the different stock conditions of the AZ31 magnesium alloy.In the process of spinning experiment,it has analyzed the influence of spinning technological parameter on the end parts quality,and brought in the scheme of controlling spinning technological parameter. According to the numerical simulation and trial results,it has perfected the spinning technique,analyzed the mechanism of production of the blemish,brought in the relevant controlling measures.
Meanwhile,through metal flowing process analyse in the spinning process of AZ31 magnesium alloy,influencing this decisive factor of plasticity are deformation temperature and speed. And has proved to the result of simulation through the experiment, show as a result:Because the spinning technology has adopted the rational craft parameter experemrnt, have avoided disadvantageous phenomenon in the spinning process. Through the optimization design of the mould and the metal is filled with performance better,has achieved the anticipated goal.
引文
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2 日本塑性加工学会.旋压成形技术.陈敬之译,北京:机械工业出版社,1988
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5 Ismail Nawi,S.M.Mahdavian-Hydrodynamic lubrication analysis he tube spinning process. wear,1998(200):145～153
6 GE EN.T(Ed) , Nee.A.YC.(Ed.).5Sth Asia Pacific Conference on Materials processing. Journal of Materials Processing Tech1010812001(113):788～789
7 Matsunok.Recent Research and Development in Meta Forming in Japan.Jouinal of Materials Processing Technology1997,6:1～3
8 Kawai,K,Yang,L.N,Kudo H. A flexible shear spinnig of truncated conical shells with a general-PU113ose mandrel.Journal of Materials Processing Technology,2001(113):28～33
9 张津,章宗和.镁合金及应用,北京:化学工业出版社,2004.
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14 王成和.旋压技术.北京:机械工业出版社,1986:1～13,637～689
15 日本塑性加工学会.旋压成形技术.机械工业出版社,1988
16 陈适先,贾文铎等.强力旋压工艺与设备.国防工业出版社,1986
17 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
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22 A.Ben-Artzy,A.Shtechman,N.Ben-Ari,D.Dayan,Plastic deformation of wrought magnesium alloys AZ31,ZK60,Proceeding of the second Israeli nternational Conference on Magnesium Science & Technology,22-24 February,2000,Dead sea,Israel,pp151～158
23 吕炎,徐福昌,薛克敏,许沂.镁合金上机匣等温精锻工艺的研究.哈尔滨工业大学学报.2000,32(4):127～129
24 吕炎,单德彬,薛克敏.大型复杂形状锻件等温精锻工艺的研究.第七界全国锻压学术年会论文集,北京:航空工业出版社,1999 年 11 月,厦门,76～79
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29 谢水生,李兴刚,江运喜.镁合金汽车轮毅半固态触变成形的刚-粘塑性有限元分析.塑性工程学报.Vol.12,No.2
30 启炽,张新建,崔建忠.镁合金及其成形工工艺与应用状况.材料导报,2002,12(12):12～15
31 Cray J E,Luan B. Protective Coatings on Magnesium and Its Alloys-a criticalReview[J].Journal of Alloys and Compounds, 2002,336(1-2):88～113
32 武增臣,龙思远,徐绍勇.镁合金轮毂的一种新型挤压铸造方法.铸造.Vol. 54,No.9,Sep.2005
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35 杜坤,杨合.多道次普旋技术研究进展.机械科学与技术,200120(4):558～560
36 Wang Qiang,Z-R.Wang.Numerical Simulation and Experimental Study on The New Process of Two-Roller Bending Spinning.Advanced Technology of Plasticity 1993-Proceeding of the Fourth International Conference on Technology of plastici, VOl.3:1387～1390
37 张利鹏,刘智冲,周宏宇.筒形件强力旋压成形特点及变形规律.农机化研究.2006,(2):28～30
38 赵宪明,吴迪,吕炎.筒形件正旋旋压力及位移分布规律的有限元分析[J].塑性工程学报,2002,7(4):56～59
39 赵云豪.旋压技术与应用[M].北京:北京有色金属研究总院加工工程研究中心,2002.
40 卫原平,王轶为.工艺参数对筒形件强力旋压过程的影响.模具技术,2000.No.4
41 赵宪明.筒形件强力旋压三维弹塑性有限元分析及实验研究[D].黑龙江:哈尔滨工业大学,1995
42 李超龄.筒形件强力旋压过程的有限元数值模拟[D].西安:西北工业大学,2004
43 MohriT,MabuchiM,Nakamura M,et al. Microstructural evolution and super plasticity of rolled Mg9Al1Zn[J].Mater Sci EngA,2000,A290:139～144.
44 IonS E,Hum phreysF J,White S H.Dynamic recrystallization and development of microstructure during the high temperature deformation of magnesium [J].ActaMetall,1982,30:1909～1919.
45 陈振华等.变形镁合金.北京:化学工业出版社,2005
46 陈振华等.镁合金.北京:化学工业出版社,2004
47 汪凌云,黄光胜等.变形 AZ31 镁合金的晶粒细化.中国有色金属学报, 2003, 13 (2):594～597.
48 翟秋亚,王智民等.挤压变形对 AZ31 镁合金组织和性能的影响.西安理工大学学报, 2002,18(3):254～258.
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2 日本塑性加工学会.旋压成形技术.陈敬之译,北京:机械工业出版社,1988
3 M. M. ELKhabeery, M.Fattouh, M.N.E.Sheikh-On the Conventional Simple Spinning of Cylindrical Aluminum Cups. International Jurnal of Machine Tools & Mmufacture,1991(2):203～419
4 R. RShghal,P.K.SaxeIIAR. Prakash-Estimation of Power in The Shearspining of Long Tubes in Hard-to-Work Materials.Journal Of Materials Processing TechI Ioiogy,1990(23):29～40
5 Ismail Nawi,S.M.Mahdavian-Hydrodynamic lubrication analysis he tube spinning process. wear,1998(200):145～153
6 GE EN.T(Ed) , Nee.A.YC.(Ed.).5Sth Asia Pacific Conference on Materials processing. Journal of Materials Processing Tech1010812001(113):788～789
7 Matsunok.Recent Research and Development in Meta Forming in Japan.Jouinal of Materials Processing Technology1997,6:1～3
8 Kawai,K,Yang,L.N,Kudo H. A flexible shear spinnig of truncated conical shells with a general-PU113ose mandrel.Journal of Materials Processing Technology,2001(113):28～33
9 张津,章宗和.镁合金及应用,北京:化学工业出版社,2004.
10 刘正,张奎,曾小勤著,镁基轻质合金理论基础及其应用.北京:机械工业出版社,2002.
11 有色金属及其热处理,国防工业出版社,1981
12 赖华清,范宏训.汽车铝合金轮毂的成形工艺.金属成形工艺,2002,(6):6
13 陈适先.强力旋压工艺与设备.北京:国防工业出版社,1986:1～21
14 王成和.旋压技术.北京:机械工业出版社,1986:1～13,637～689
15 日本塑性加工学会.旋压成形技术.机械工业出版社,1988
16 陈适先,贾文铎等.强力旋压工艺与设备.国防工业出版社,1986
17 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
18 赵云豪,张顺福.国内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
19. 赵鸿.铝在汽车上的应用.汽车工艺与材料,1997 年第 1 期
20. 陈世平.汽车轻量化及其材料.汽车工艺与材料,1995 年第 4 期
21 H.Friedrich.s.Schumarn,The second age of magnesium research strategies to bring the automotive industry,s vision to reality,Proceeding of the second Israeli International Conference on Magnesium Science & Technology,22-24 February, 2000,Dead sea,Israel,pp9～18
22 A.Ben-Artzy,A.Shtechman,N.Ben-Ari,D.Dayan,Plastic deformation of wrought magnesium alloys AZ31,ZK60,Proceeding of the second Israeli nternational Conference on Magnesium Science & Technology,22-24 February,2000,Dead sea,Israel,pp151～158
23 吕炎,徐福昌,薛克敏,许沂.镁合金上机匣等温精锻工艺的研究.哈尔滨工业大学学报.2000,32(4):127～129
24 吕炎,单德彬,薛克敏.大型复杂形状锻件等温精锻工艺的研究.第七界全国锻压学术年会论文集,北京:航空工业出版社,1999 年 11 月,厦门,76～79
25 刘满平,马春江,王渠东等.工业态 AZ31 镁合金的超塑性变形行为.中国有色金属学报,2002(4)797～801
26 王祝堂.铝合金轮毂的发展.轻合金加工技术. 1994,Vol.22,No3
27 王德林.AZ31 镁合金轿车轮毂温成形工艺研究[M].2005(2),太原,8
28 蔡锁歧.镁合金汽车车轮重力铸造研究[J].铸造技术.2001,(5):8～10
29 谢水生,李兴刚,江运喜.镁合金汽车轮毅半固态触变成形的刚-粘塑性有限元分析.塑性工程学报.Vol.12,No.2
30 启炽,张新建,崔建忠.镁合金及其成形工工艺与应用状况.材料导报,2002,12(12):12～15
31 Cray J E,Luan B. Protective Coatings on Magnesium and Its Alloys-a criticalReview[J].Journal of Alloys and Compounds, 2002,336(1-2):88～113
32 武增臣,龙思远,徐绍勇.镁合金轮毂的一种新型挤压铸造方法.铸造.Vol. 54,No.9,Sep.2005
33 张先宏,崔振山,阮雪榆.AZ31B 成形性能及流变应力.上海交通大学学报,2003(12):1874～1877
34 李云生,邢吉丰.国内普通旋压技术概况.锻压机械,1984,(4):29～32
35 杜坤,杨合.多道次普旋技术研究进展.机械科学与技术,200120(4):558～560
36 Wang Qiang,Z-R.Wang.Numerical Simulation and Experimental Study on The New Process of Two-Roller Bending Spinning.Advanced Technology of Plasticity 1993-Proceeding of the Fourth International Conference on Technology of plastici, VOl.3:1387～1390
37 张利鹏,刘智冲,周宏宇.筒形件强力旋压成形特点及变形规律.农机化研究.2006,(2):28～30
38 赵宪明,吴迪,吕炎.筒形件正旋旋压力及位移分布规律的有限元分析[J].塑性工程学报,2002,7(4):56～59
39 赵云豪.旋压技术与应用[M].北京:北京有色金属研究总院加工工程研究中心,2002.
40 卫原平,王轶为.工艺参数对筒形件强力旋压过程的影响.模具技术,2000.No.4
41 赵宪明.筒形件强力旋压三维弹塑性有限元分析及实验研究[D].黑龙江:哈尔滨工业大学,1995
42 李超龄.筒形件强力旋压过程的有限元数值模拟[D].西安:西北工业大学,2004
43 MohriT,MabuchiM,Nakamura M,et al. Microstructural evolution and super plasticity of rolled Mg9Al1Zn[J].Mater Sci EngA,2000,A290:139～144.
44 IonS E,Hum phreysF J,White S H.Dynamic recrystallization and development of microstructure during the high temperature deformation of magnesium [J].ActaMetall,1982,30:1909～1919.
45 陈振华等.变形镁合金.北京:化学工业出版社,2005
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