身管径向锻造过程解析分析与数值模拟
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摘要
径向锻造是一种开放式锻造工艺,擅长加工长轴类零件及具有内部形状的管状零件,如枪管膛线等。径向锻造技术作为身管制造的一种方法,由于残余压缩应力的存在,可以提高身管的强度和疲劳性能。由于身管径向锻造工艺涉及的物理过程较为复杂,工艺参数数目较多,因此应用解析法和数值法对其工艺过程进行分析是非常必要的。
运用解析法建立了径向锻造过程力学方程、应变方程及变形方程,通过具体实例分析了线膛精锻过程中工艺参数对锻打力的影响,利用前人的实验数据验证了解析解的准确性。
应用Abaqus软件建立了二维径向锻造有限元模型,研究了线膛径向锻造过程中的金属流动情况和变形情况,分析了锻件的应变及残余应力分布状况,提出了夹持压强下限的选取原则。
应用Abaqus软件建立了三维径向锻造有限元模型,研究了金属径向、周向、轴向流动情况；对二维、三维两种模型之间的锻打力换算方法以及主轴转速对锻打力的影响进行探讨。
结合解析法和有限单元法,对工件和弹性杆构成的旋转振动系统进行数学建模,分析了锻造过程中工件的旋转运动状态,讨论了弹性杆扭转刚度的选取原则,为实际加工过程弹性杆的选取和设计提供理论依据。
建立了膛线成型的有限元模型,研究了金属嵌入膛线沟槽过程的金属流动情况,讨论了心轴结构及锻造比对膛线成型的影响,为实际加工过程工艺参数的选取提供依据。
结合Fatigue软件对锤头、心轴的使用寿命及疲劳特性进行分析,研究了模具的应力状态。
Radial forging is an open forging process for reducing the diameters of shafts, tubes, as well as for creating internal profiles for tubes such as gun barrels. Radial forging process can improve the strength and fatigue property of the tubes as the residual compressive stress exists. Analysis of radial forging process using analytical method and numerical method is very necessary as the physical process is very complex during radial forging process.
Analytical method is used to create the function to describe the stress、strain and deformation property during the radial forging process. The effect of process parameters on forging load is analyzed by a concrete example. The reliability of result is verified by the experimental results from the references.
The 2D axisymmetric FEA model is created by the commercial finite element code Abaqus to analyze the metal flow and deformation of the tube. Besides that, the strain and residual stress are investigated and the minimum back pressure is proposed.
An entire 3D FEA model is created to investigate the metal flow in radial、circumferential and axial directions. The effects of the spindle speed on the forging load and translation between the forging load calculated by 2D and 3D FEA model is considered.
Both mathematical analytical model and FEA model of the vibration system consisted of the work-piece and the spring bar are created. The movement of the work-piece and the determination criteria of the torsional stiffness are discussed. The results can provide the theoretical basis to design the spring bar for the actual process.
A 3D axisymmetric FEA model is bulit to simulate the deformation of the barrel rifling during the radial forging process and metal flow during the rifling forming process is analyzed. Additionally, the influence of the mandrel and the percentage of reduction on deformation are investigated in order to optimize the process parameters.
The service life and fatigue property of the die and mandrel are analyzed by the commercial code Fatigue and the stress is also investigated.
运用解析法建立了径向锻造过程力学方程、应变方程及变形方程,通过具体实例分析了线膛精锻过程中工艺参数对锻打力的影响,利用前人的实验数据验证了解析解的准确性。
应用Abaqus软件建立了二维径向锻造有限元模型,研究了线膛径向锻造过程中的金属流动情况和变形情况,分析了锻件的应变及残余应力分布状况,提出了夹持压强下限的选取原则。
应用Abaqus软件建立了三维径向锻造有限元模型,研究了金属径向、周向、轴向流动情况；对二维、三维两种模型之间的锻打力换算方法以及主轴转速对锻打力的影响进行探讨。
结合解析法和有限单元法,对工件和弹性杆构成的旋转振动系统进行数学建模,分析了锻造过程中工件的旋转运动状态,讨论了弹性杆扭转刚度的选取原则,为实际加工过程弹性杆的选取和设计提供理论依据。
建立了膛线成型的有限元模型,研究了金属嵌入膛线沟槽过程的金属流动情况,讨论了心轴结构及锻造比对膛线成型的影响,为实际加工过程工艺参数的选取提供依据。
结合Fatigue软件对锤头、心轴的使用寿命及疲劳特性进行分析,研究了模具的应力状态。
Radial forging is an open forging process for reducing the diameters of shafts, tubes, as well as for creating internal profiles for tubes such as gun barrels. Radial forging process can improve the strength and fatigue property of the tubes as the residual compressive stress exists. Analysis of radial forging process using analytical method and numerical method is very necessary as the physical process is very complex during radial forging process.
Analytical method is used to create the function to describe the stress、strain and deformation property during the radial forging process. The effect of process parameters on forging load is analyzed by a concrete example. The reliability of result is verified by the experimental results from the references.
The 2D axisymmetric FEA model is created by the commercial finite element code Abaqus to analyze the metal flow and deformation of the tube. Besides that, the strain and residual stress are investigated and the minimum back pressure is proposed.
An entire 3D FEA model is created to investigate the metal flow in radial、circumferential and axial directions. The effects of the spindle speed on the forging load and translation between the forging load calculated by 2D and 3D FEA model is considered.
Both mathematical analytical model and FEA model of the vibration system consisted of the work-piece and the spring bar are created. The movement of the work-piece and the determination criteria of the torsional stiffness are discussed. The results can provide the theoretical basis to design the spring bar for the actual process.
A 3D axisymmetric FEA model is bulit to simulate the deformation of the barrel rifling during the radial forging process and metal flow during the rifling forming process is analyzed. Additionally, the influence of the mandrel and the percentage of reduction on deformation are investigated in order to optimize the process parameters.
The service life and fatigue property of the die and mandrel are analyzed by the commercial code Fatigue and the stress is also investigated.
引文
[1]勃拉贡拉沃夫.枪管制造.国防工业出版社,1956
[2]樊黎霞,刘力力,刘庆东,董雪花.身管线膛精锻加工过程的数值分析.兵工学报.2009(8)：1098-1102
[3]黄少东.发展塑性成型技术,提高兵器行业制造水平.2006中国科协年会.2006：242-247
[4]Charle F. Barth. Improved materials and manufacturing methods for gun barrels. National Technical Information Service,1975:1-3
[5]H. Hojas. GFM precision forging machines. Technical literature, GFM Corp,1976:10
[6]Sachs, Baldwin. Stress analysis of tube sinking. Journal of Engineering for Industry. American Society of Mechanical Engineers,1946(9):655-662
[7]Kegg. Mechanics of the rotary swaging process. Journal of Engineering for Industry, 1964(9):317-325
[8]G.D. Lahoti, T. Altan. Analysis and optimization of the radial forging process for manufacturing gun barrels. Journal of Engineering for Industry,1976(1):265-271
[9]A. Ghaei, M.R. Movahhedy, A.Karimi Taheri. Study of the effects of die geometry on deformation in the radial forging process. Journal of Materials Processing Technology, 2005(170):156-163
[10]A. Ghaei, A.Karimi Taheri, M.R. Movahhedy. A new upper bound solution for analysis of the radial forging process. International Journal of Mechanical Sciences, 2006(48):1264-1272
[11]M. Sanjari, A.Karimi Taheri, A. Ghaei. Prediction of neutral plane and effects of the process parameters in radial forging using an upper bound solution. Journal of Materials Processing Technology,2007(186):147-153
[12]R. Paukert. Investigations into metal flow in radial forging. Analysis of the CIRP, 1983(1):211-217
[13]P. Joseph, Rajiv Shivpuri, Brett Painter. Application of the finite-element method to the radial forging of large diameter tubes. Journal of Materials Processing Technology, 1995(49):57-74
[14]T. Altan. Numerical and experimental modeling of multiple pass radial forging of Alloy 718. The Ohio State University,1994:84-140
[15]A. Ameli, M.R. Movahhedy. A parametric study on residual stresses and forging load in cold radial forging process. The International Journal of Advanced Manufacturing Technology,2007(33):7-17
[16]A. Ameli, M.R. Movahhedy. Die design for the radial forging process using 3D FEM. Journal of Materials Processing Technology.2007(182):534-539
[17]J. Chen, K. Chandrashekhare. Three-dimensional nonlinear finite element analysis of hot radial forging process for large diameter tubes. Materials and Manufacturing Processes,2010(25):669-678
[18]A.K. Sahoo, M.K. Tiwari, A.R. Mileham. Six sigma based approach to optimize radial forging operation variables. Journal of Materials Processing Technology,2008(202): 125-136
[19]M. Sanjari, A. Karimi Taheri, M.R. Movahedi. An optimization method for radial forging process using ANN and Taguchi method. The Intnational Journal of Advanced Manufacturing Technology,2009(40):776-784
[20]解卓明.四锤头精锻机国产化的初探.锻压机械,1995(5)：41-42
[21]李桂元.枪管旋转精锻.现代兵器,1981：33-36
[22]李桂元.径向锻造厚壁炮管.现代兵器,1981：39-44
[23]李艳萍.车轴径向锻造过程分析.锻压设备与制造技术,2007(1)：31-33
[24]韩星会.轴类零件径向锻造压入量研究.锻压设备与制造技术,2006(6)：75-78
[25]Liu Lili. Study of residual stress in the barrel processed by the radial forging. The Second International Conference on Information and Computing Science.2009: 131-134
[26]Hyperworks Release Notes.2006:8-12
[27]Cato Dorum, Odd S.Hopperstad, Magnus Langseth, Hariaokto Hooputra, Stefan Weyer. Numerical modeling of the crashworthiness of thin-walled cast magnesium components. ABAQUS Users'Conference,2006:203-214
[28]李剑荣,虞吉林,魏志刚.冲击载荷下钨合金圆台试件绝热剪切变形局部化的数值模拟.爆炸与冲击,2002：257-262
[29]Lin Hua, Xinghui Han.3D FE modeling simulation of cold rotary forging of a cylinder workpiece. Materials and Design,2009(30):2133-2142
[30]施丽娟,林铸明,崔维成.浮桥结构在移动载荷作用下的振动响应.海洋工程,2003：6-17
[31]Lynn M.Powers. Using ABAQUS scripting interface for materials evaluation and life prediction. ABAQUS Users'Conference,2006:377-387
[32]鲍荣浩,卢文浩.ABAQUS前处理程序二次开发在蜂窝材料中的应用.工程设计 学报,2003：330-333
[33]周传月,郑红霞,罗慧强.MSC.Fatigue疲劳分析应用与实例.科学出版社,2005：8-24
[34]徐秉业.应用弹塑性力学.清华大学出版社,1995：56-58
[35]刘宏文.材料力学(下).高等教育出版社,1991：150-152
[36]A. Uhlig. Investigation of the motions and the forces in radial swaging. Doctoral dissertation(German), Technical University Hannover,1964.
[37]Gordon R. Johnson,William H.Cook. A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. Proceedings of Seventh International Symposium on Ballistics,1983:541-547
[38]Riqiang Liang, Akhtar S.Khan. A critical review of experimental results and constitutive models for BCC and FCC metals over a wide range of strain rates and temperatures. International Journal of Plasticity,1999(15):963-980
[39]郝南海,常志梁.塑性成型力学.兵器工业出版社,2001：11-13
[40]V. Hamel, J.M. Roelandt, J.N. Gacel, F. Schmit. Finite element modeling of clinch forming with automatic remeshing. Compters and Structures,2000(185):185-200
[41]Atzema EH, J. Huetink. Finite element analysis of forward-backward extrusion using ALE techniques. Proceedings of International Conference of Numerical Methods in Industrial Forming Processes,1995:383-388
[42]庄新村,赵震,向华,李从心.ALE有限元法在金属塑性成型领域的研究进展.塑性工程学报,2008(1)：1-6
[43]Abaqus/CAE User's Manual.14.6
[44]雷玉成,汪建敏,贾志宏.金属材料成型原理.化学工业出版社,2006：128-131
[45]虞松.金属塑性成形过程三维有限元六面体网格自动生成算法及数值模拟关键技术研究.山东大学博士论文,2004：7-8
[46]Steven E.Benzley, Ernest Perry, Greg Sjaardema. Comparison of all-hexahedrala and all-tetrahedral finite element meshes for elastic and elasto-plastic analysis. In 4th International Meshing Roundtable,1995:179-191
[47]V.N. Parthasarathy, C.M. Graichen, A.F. Hathaway. A comparison of tetrahedron quality measures. Finite Elements in Analysis and Design,1993(15):255-261
[48]杨建刚.旋转机械振动分析与工程应用.中国电力出版社,2007：7-10
[49]庄茁,张帆,岑松等.ABAQUS非线性有限元分析与实例.科学出版社,2005：211-213
[50]Ralph I.Stephens, Ali Fatemi, Robert R. Stephens, Henry O.Fuchs. Metal fatigue in engineering. New York(Wiley),2001:59-90
[51]MSC.FATIGUE User's Guide. Fatigue Theory 13.2:1144
[2]樊黎霞,刘力力,刘庆东,董雪花.身管线膛精锻加工过程的数值分析.兵工学报.2009(8)：1098-1102
[3]黄少东.发展塑性成型技术,提高兵器行业制造水平.2006中国科协年会.2006：242-247
[4]Charle F. Barth. Improved materials and manufacturing methods for gun barrels. National Technical Information Service,1975:1-3
[5]H. Hojas. GFM precision forging machines. Technical literature, GFM Corp,1976:10
[6]Sachs, Baldwin. Stress analysis of tube sinking. Journal of Engineering for Industry. American Society of Mechanical Engineers,1946(9):655-662
[7]Kegg. Mechanics of the rotary swaging process. Journal of Engineering for Industry, 1964(9):317-325
[8]G.D. Lahoti, T. Altan. Analysis and optimization of the radial forging process for manufacturing gun barrels. Journal of Engineering for Industry,1976(1):265-271
[9]A. Ghaei, M.R. Movahhedy, A.Karimi Taheri. Study of the effects of die geometry on deformation in the radial forging process. Journal of Materials Processing Technology, 2005(170):156-163
[10]A. Ghaei, A.Karimi Taheri, M.R. Movahhedy. A new upper bound solution for analysis of the radial forging process. International Journal of Mechanical Sciences, 2006(48):1264-1272
[11]M. Sanjari, A.Karimi Taheri, A. Ghaei. Prediction of neutral plane and effects of the process parameters in radial forging using an upper bound solution. Journal of Materials Processing Technology,2007(186):147-153
[12]R. Paukert. Investigations into metal flow in radial forging. Analysis of the CIRP, 1983(1):211-217
[13]P. Joseph, Rajiv Shivpuri, Brett Painter. Application of the finite-element method to the radial forging of large diameter tubes. Journal of Materials Processing Technology, 1995(49):57-74
[14]T. Altan. Numerical and experimental modeling of multiple pass radial forging of Alloy 718. The Ohio State University,1994:84-140
[15]A. Ameli, M.R. Movahhedy. A parametric study on residual stresses and forging load in cold radial forging process. The International Journal of Advanced Manufacturing Technology,2007(33):7-17
[16]A. Ameli, M.R. Movahhedy. Die design for the radial forging process using 3D FEM. Journal of Materials Processing Technology.2007(182):534-539
[17]J. Chen, K. Chandrashekhare. Three-dimensional nonlinear finite element analysis of hot radial forging process for large diameter tubes. Materials and Manufacturing Processes,2010(25):669-678
[18]A.K. Sahoo, M.K. Tiwari, A.R. Mileham. Six sigma based approach to optimize radial forging operation variables. Journal of Materials Processing Technology,2008(202): 125-136
[19]M. Sanjari, A. Karimi Taheri, M.R. Movahedi. An optimization method for radial forging process using ANN and Taguchi method. The Intnational Journal of Advanced Manufacturing Technology,2009(40):776-784
[20]解卓明.四锤头精锻机国产化的初探.锻压机械,1995(5)：41-42
[21]李桂元.枪管旋转精锻.现代兵器,1981：33-36
[22]李桂元.径向锻造厚壁炮管.现代兵器,1981：39-44
[23]李艳萍.车轴径向锻造过程分析.锻压设备与制造技术,2007(1)：31-33
[24]韩星会.轴类零件径向锻造压入量研究.锻压设备与制造技术,2006(6)：75-78
[25]Liu Lili. Study of residual stress in the barrel processed by the radial forging. The Second International Conference on Information and Computing Science.2009: 131-134
[26]Hyperworks Release Notes.2006:8-12
[27]Cato Dorum, Odd S.Hopperstad, Magnus Langseth, Hariaokto Hooputra, Stefan Weyer. Numerical modeling of the crashworthiness of thin-walled cast magnesium components. ABAQUS Users'Conference,2006:203-214
[28]李剑荣,虞吉林,魏志刚.冲击载荷下钨合金圆台试件绝热剪切变形局部化的数值模拟.爆炸与冲击,2002：257-262
[29]Lin Hua, Xinghui Han.3D FE modeling simulation of cold rotary forging of a cylinder workpiece. Materials and Design,2009(30):2133-2142
[30]施丽娟,林铸明,崔维成.浮桥结构在移动载荷作用下的振动响应.海洋工程,2003：6-17
[31]Lynn M.Powers. Using ABAQUS scripting interface for materials evaluation and life prediction. ABAQUS Users'Conference,2006:377-387
[32]鲍荣浩,卢文浩.ABAQUS前处理程序二次开发在蜂窝材料中的应用.工程设计 学报,2003：330-333
[33]周传月,郑红霞,罗慧强.MSC.Fatigue疲劳分析应用与实例.科学出版社,2005：8-24
[34]徐秉业.应用弹塑性力学.清华大学出版社,1995：56-58
[35]刘宏文.材料力学(下).高等教育出版社,1991：150-152
[36]A. Uhlig. Investigation of the motions and the forces in radial swaging. Doctoral dissertation(German), Technical University Hannover,1964.
[37]Gordon R. Johnson,William H.Cook. A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. Proceedings of Seventh International Symposium on Ballistics,1983:541-547
[38]Riqiang Liang, Akhtar S.Khan. A critical review of experimental results and constitutive models for BCC and FCC metals over a wide range of strain rates and temperatures. International Journal of Plasticity,1999(15):963-980
[39]郝南海,常志梁.塑性成型力学.兵器工业出版社,2001：11-13
[40]V. Hamel, J.M. Roelandt, J.N. Gacel, F. Schmit. Finite element modeling of clinch forming with automatic remeshing. Compters and Structures,2000(185):185-200
[41]Atzema EH, J. Huetink. Finite element analysis of forward-backward extrusion using ALE techniques. Proceedings of International Conference of Numerical Methods in Industrial Forming Processes,1995:383-388
[42]庄新村,赵震,向华,李从心.ALE有限元法在金属塑性成型领域的研究进展.塑性工程学报,2008(1)：1-6
[43]Abaqus/CAE User's Manual.14.6
[44]雷玉成,汪建敏,贾志宏.金属材料成型原理.化学工业出版社,2006：128-131
[45]虞松.金属塑性成形过程三维有限元六面体网格自动生成算法及数值模拟关键技术研究.山东大学博士论文,2004：7-8
[46]Steven E.Benzley, Ernest Perry, Greg Sjaardema. Comparison of all-hexahedrala and all-tetrahedral finite element meshes for elastic and elasto-plastic analysis. In 4th International Meshing Roundtable,1995:179-191
[47]V.N. Parthasarathy, C.M. Graichen, A.F. Hathaway. A comparison of tetrahedron quality measures. Finite Elements in Analysis and Design,1993(15):255-261
[48]杨建刚.旋转机械振动分析与工程应用.中国电力出版社,2007：7-10
[49]庄茁,张帆,岑松等.ABAQUS非线性有限元分析与实例.科学出版社,2005：211-213
[50]Ralph I.Stephens, Ali Fatemi, Robert R. Stephens, Henry O.Fuchs. Metal fatigue in engineering. New York(Wiley),2001:59-90
[51]MSC.FATIGUE User's Guide. Fatigue Theory 13.2:1144