弹膛成形时的工艺参数影响分析及知识库的建立
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摘要
弹膛是枪管的重要组成部分,其主要作用是容纳枪弹,保证枪弹发射时能够正确定位和射击。身管线弹膛采用径向锻造工艺一起锻出,不但能保证锻件的高精度,而且可以减少后续机械加工,还能使身管线膛与弹膛保持极高的同轴度。基于国内身管线弹膛精锻工艺还不够完善的现状,对影响身管弹膛精锻成形的工艺参数进行分析就具备重要的现实意义。
本文针对影响身管弹膛精锻成形的主要工艺参数,运用有限元分析软件ABAQUS对身管线弹膛精锻的整个过程进行数值模拟,并用解析法对锻打位置的几何参量进行求解,完成了如下工作：
(1)依照身管线弹膛精锻过程中材料的塑性成形机理,用解析法对影响弹膛成形的关键参数即抬锤位置进行求解,得出了弹膛成形的必要条件。
(2)通过数值模拟展示了身管弹膛精锻过程中出现的锻造缺陷；依据毛坯成形过程中材料的流动情况,对锻造缺陷的形成机理进行了分析。
(3)分析身管精锻过程中主要工艺参数,包括抬锤位置、轴向进给速度、夹持压强等对弹膛成形的影响；对锤头和芯棒的结构进行分析,讨论了不同芯棒弹膛锥角与锤头角度的匹配关系。
(4)对精锻过程中各工艺参数对弹膛成形的影响进行汇总并建立知识库,重点对实现其中主要模块的关键技术进行研究,以期为实际生产提供直观实用的理论支持。
The chamber is one important part of barrel while its leading roles are holding bullets and guaranteeing the orientation when launching bullets. When the rifling and chamber of barrel are produced at same time with the radial forging process, it does not only guarantee higher forging precision and less following machine processing, but also let the rifling and chamber of barrel maintain extremely high proper alignment. For that the domestic radial forging technology of barrel is insufficiently perfect at the present, it is significant to do researches on the process parameters' influence analysis over the forming of chamber with the radial forging technology.
In view of the influence of the main process parameters over chamber's forming in the radial forging of barrel, numerical simulation of chamber's forming process is carried on with the finite element analysis software ABAQUS and the geometry parameters of the forging position are calculated with the analysis method. The following works are completed in this thesis.
(1) During the chamber's forming process of the radial forging, the position of lifting hammer is a key parameter of which influence chamber's forming. According to the material's plastic forming mechanism of barrel, the perfect location of lifting hammer is figured out with the analysis method.
(2) The forging flaws during the radial forging process of chamber are showed by the numerical simulation. The formation mechanism of the forging flaws is analyzed base on the material's flow status of barrel during the forming process.
(3) During the radial forging process of the barrel's rifling and chamber, the influences of major process parameters which include lifting position of hammer, the axial feed speed and the clamp's pressure are analyzed. The matching relations between different cone angles of the mandrel and the hammer's cone angles are discussed.
(4) The various process parameters' influences to the chamber's forming are compiled and the knowledge library about the chamber's forging is established which may provide direct-viewing and practical theory support for the actual production.
本文针对影响身管弹膛精锻成形的主要工艺参数,运用有限元分析软件ABAQUS对身管线弹膛精锻的整个过程进行数值模拟,并用解析法对锻打位置的几何参量进行求解,完成了如下工作：
(1)依照身管线弹膛精锻过程中材料的塑性成形机理,用解析法对影响弹膛成形的关键参数即抬锤位置进行求解,得出了弹膛成形的必要条件。
(2)通过数值模拟展示了身管弹膛精锻过程中出现的锻造缺陷；依据毛坯成形过程中材料的流动情况,对锻造缺陷的形成机理进行了分析。
(3)分析身管精锻过程中主要工艺参数,包括抬锤位置、轴向进给速度、夹持压强等对弹膛成形的影响；对锤头和芯棒的结构进行分析,讨论了不同芯棒弹膛锥角与锤头角度的匹配关系。
(4)对精锻过程中各工艺参数对弹膛成形的影响进行汇总并建立知识库,重点对实现其中主要模块的关键技术进行研究,以期为实际生产提供直观实用的理论支持。
The chamber is one important part of barrel while its leading roles are holding bullets and guaranteeing the orientation when launching bullets. When the rifling and chamber of barrel are produced at same time with the radial forging process, it does not only guarantee higher forging precision and less following machine processing, but also let the rifling and chamber of barrel maintain extremely high proper alignment. For that the domestic radial forging technology of barrel is insufficiently perfect at the present, it is significant to do researches on the process parameters' influence analysis over the forming of chamber with the radial forging technology.
In view of the influence of the main process parameters over chamber's forming in the radial forging of barrel, numerical simulation of chamber's forming process is carried on with the finite element analysis software ABAQUS and the geometry parameters of the forging position are calculated with the analysis method. The following works are completed in this thesis.
(1) During the chamber's forming process of the radial forging, the position of lifting hammer is a key parameter of which influence chamber's forming. According to the material's plastic forming mechanism of barrel, the perfect location of lifting hammer is figured out with the analysis method.
(2) The forging flaws during the radial forging process of chamber are showed by the numerical simulation. The formation mechanism of the forging flaws is analyzed base on the material's flow status of barrel during the forming process.
(3) During the radial forging process of the barrel's rifling and chamber, the influences of major process parameters which include lifting position of hammer, the axial feed speed and the clamp's pressure are analyzed. The matching relations between different cone angles of the mandrel and the hammer's cone angles are discussed.
(4) The various process parameters' influences to the chamber's forming are compiled and the knowledge library about the chamber's forging is established which may provide direct-viewing and practical theory support for the actual production.
引文
[1]韩育礼.枪炮身管设计原理[M].北京：国防工业出版社,1982
[2]《步兵自动武器及弹药设计手册》编委组.步兵自动武器及弹药设计手册(中册)[M].国防工业出版社,1977
[3]勃拉贡拉沃夫.枪管制造[M].北京：国防工业出版社,1956
[4]Charles F.Barth. Improved materials and manufacturing methods for gun barrels[G]. National Technical Information Service,1975:27-30
[5]何润华.弹膛精锻加工过程数值模拟及工艺参数优化[D].南京理工大学硕士学位论文,2008
[6]崔世强.旋转锻造[J].锻压技术新讲座,2005
[7]夏华,胡亚民,袁亮.径向锻造的工艺原理和径向锻造机的应用[G].首届锻压装备与制造技术论坛论文集,2004
[8]Joseph P.Domblesky, Rajiv Shivpuri, Taylan Altan. A review of radial forging technology including perform design for process optimization[G],1994
[9]沈阳第一锻造厂.精密锻轴工艺[M].机械工业出版社,1974
[10]吕炎.锻造工艺学[M].北京：机械工业出版社,1995
[11]吕炎.锻压成形理论与工艺[M].北京：机械工业出版社,1991
[12]Rauschnabel E, Schmidt V. Modern application of radial forging and swaging in the automotive industry[J]. Journal of Material Processing Technology,1992(35):371-383
[13]解卓明.四锤头精锻机国产化的初探[J].锻压机械,1995(5)：41-42
[14]解卓明.四锤头精锻机研发工作的现状调查[J].大连铁道学院,锻压技术,2004(1)：21-23
[15]李艳萍.车轴径向锻造过程分析[J].锻压设备与制造技术,2007(1)：31-33
[16]王振范,胡宗式.径向锻造终锻过程的流函数法解析[J].东北大学学报,1994,15(1)：35-39
[17]董节功,周旭东,朱锦洪等.径向锻造三维成形锻透性的数值模拟[J].机械工程材料,2007,31(3)：76-78
[18]Liu Lili. Study of residual stress in the barrel process by the radial forging[J]. The Second International Conference on Information and Computing Science,2009:131-134
[19]韩星会.轴类零件径向锻造压入量研究[J].锻压设备与制造技术,2006(6)：75-78
[20]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[J].兵工学报,2009,30(8)：1098-1102
[21]G.D. Lahoti, T. Altan. Analysis and optimization of the radial forging process for manufacturing gun barrels[J]. Journal of Engineering for Industry,1976(1):265-271
[22]A. Ghaei, M.R. Movahhedy, A.Karimi Taheri. Study of the effects of die geometry on deformation in the radial forging process[J]. Journal of Materials Processing Technology, 2005(170):156-163
[23]A. Ghaei, A.Karimi Taheri, M.R. Movahhedy. A new upper bound solution for analysis of the radial forging process [J]. International Journal of Mechanical Sciences, 2006(48):1264-1272
[24]Sogawa S, Suzuki Y, Uehara N. Temperature transition and deformation process of inconel 718 during rotary forging[R]. Daido steel company, Japan,1990:1-10
[25]Domblesky JP, Shivpuri R. Development and validation of a finite element model for multiple-pass radial forging[J]. Journal of Material Processing and Technology,1995(55): 432-441
[26]A.Ghaei, M.R.Movahhedy, A.Karimi Taheri. Finite element modeling simulation of radial forging tubes without mandrel[J]. Materials and Design,2008(29):867-872
[27]Su-Hai Hsiang. Investigation of the influence of various process parameters on the radial forging processes by the finite element method(FEM)[J]. The International Journal of Advanced Manufacturing Technology,2004(23):627-635
[28]A. Ameli, M.R. Movahhedy. A parametric study on residual stresses and forging load in cold radial forging process [J]. The International Journal of Advanced Manufacturing Technology,2007(33):7-17
[29]A. Ameli, M.R. Movahhedy. Die design for the radial forging process using 3D FEM[J]. Journal of Materials Processing Technology,2007(182):534-539
[30]Stokes M, Ed. Managing Engineering Knowledge-MOKA:Methodology for Knowledge Based Engineering Applications[C], ASME Press,2001.
[31]Andreasen M.. Integrated product development[C]. Springer Verlag, Berlin.1987.
[32]Howard C..The virtual engineer,21st Century Project Development[J].Society of Manufacturing Engineers,1998:491-495
[33]J. Kulon, D.J.Mynors, P. Broomhead. A knowledge-based engineering design tool for metal forging[J]. Journal of Materials Processing Technology,2006(177):331-335
[34]Jie Hu, Yinghong Peng, Dayong Li, Jilong Yin. Robust optimization based on knowledge discovery from metal forming simulation[J]. Journal of Materials Processing Technology,2007:698-701
[35]张胜兰,郑冬黎,郝琪.基于HyperWorks的机构优化设计技术[M].机械工业出 版社,2007
[36]Zhang Rui. Finite element analysis based on Proe, Hypermesh and Ansys[C].2008 International Conference on Computer Science and Software Engineering,2008:622-625
[37]Fang Liu, Guang Meng, Mei Zhao. Experimental and numerical analysis of BGA lead-free solder joint reliability under board-level drop impact[J]. Microelectronics Reliability, 2009(49):79-85
[38]Rajesh Kalavalapally, Ravi Penmetsa, Ramana Grandhi. Configuration design of a lightweight torpedo subjected to an underwater explosion[J]. International Journal of Impact Engineering,2009(36):343-351
[39]Cato Dorum, Odd S.Hopperstad, Magnus Langseth. Numerical modeling of the crashworthiness of thin-walled cast magnesium components[G]. ABAQUS Users' Conference,2006:203-214
[40]Stoker H.C. Developments of the arbitrary lagrangian-eulerian method in non-linear solid mechanics[C]. Applications to Forming Processes. Eindhoven, Technische Universiteit Eindhoven,1999
[41]王跃先,陈军,阮雪榆.ALE有限元方法在金属塑性加工中的应用[J].模具技术,2001(3)：1-4
[42]ABAQUS/CAE User's Manual.18.5
[43]王旭成.有限单元法[M].北京：清华大学出版社,2003
[44]王旭成,邵敏.有限单元法基本原理和数值方法[M].清华大学出版社,1997
[45]朱伯芳.有限单元法原理和应用[M].水利电力出版社,1979(3)：5-15
[46]曹金凤,石亦平.ABAQUS有限元分析常见问题解答[M].机械工业出版社,2009
[47]庄茁.ABAQUS非线性有限元分析事例[M].科学出版社,2005(1)：1-4
[48]曹文君.知识库系统原理及其应用[M].复旦大学出版社,1995(8)：11-17
[49]娄臻亮,赵震等.工程设计KBE系统(1)：概述[J].机械科学与技术,2001(5)：169-171
[50]苑伟政,杨玉起.宇航难加工材料切削加工专家系统[J].航空工艺技术,1994(5)：21-23
[51]庞思勤,张启元,于启勋.硬质合金刀具实用专家系统结构分析[J].北京理工大学博士论文,2000
[52]陈统坚,彭冠,张俊.铣削加工过程多目标优化专家系统[J].机械工程师,1998(1)：5-6
[53]邹本清,周洪玉,郑敏利.刀片槽型CAD模块的设计与实现[J].哈尔滨理工大学学报,2000(2)：42-45
[54]毛用宁.基于知识的冲压工艺设计决策系统关键技术研究[D].上海交通大学硕士学位论文,2003
[55]赵震.面向创新设计理论体系的智能冲压工艺设计KBE技术研究[D].上海交通大学博士学位论文,2002
[56]陆汝钤.世纪之交的知识工程与知识科学[M].清华大学出版社,2001(9)：315-328
[57]蒋占四,陈立平,罗年猛.最近邻事例检索相似度分析[J].计算机集成制造系统,2007(6)：1165-1168
[58]T.Y. Slonim, M. Schneider. Design issues in fuzzy case-based reasoning[J]. Fuzzy Sets and Systems,2001(117):251-267
[59]刘龙,朱林波.基于VB.NET的Pro/E二次开发关键技术[J].现代制造工程,2008：63-65
[2]《步兵自动武器及弹药设计手册》编委组.步兵自动武器及弹药设计手册(中册)[M].国防工业出版社,1977
[3]勃拉贡拉沃夫.枪管制造[M].北京：国防工业出版社,1956
[4]Charles F.Barth. Improved materials and manufacturing methods for gun barrels[G]. National Technical Information Service,1975:27-30
[5]何润华.弹膛精锻加工过程数值模拟及工艺参数优化[D].南京理工大学硕士学位论文,2008
[6]崔世强.旋转锻造[J].锻压技术新讲座,2005
[7]夏华,胡亚民,袁亮.径向锻造的工艺原理和径向锻造机的应用[G].首届锻压装备与制造技术论坛论文集,2004
[8]Joseph P.Domblesky, Rajiv Shivpuri, Taylan Altan. A review of radial forging technology including perform design for process optimization[G],1994
[9]沈阳第一锻造厂.精密锻轴工艺[M].机械工业出版社,1974
[10]吕炎.锻造工艺学[M].北京：机械工业出版社,1995
[11]吕炎.锻压成形理论与工艺[M].北京：机械工业出版社,1991
[12]Rauschnabel E, Schmidt V. Modern application of radial forging and swaging in the automotive industry[J]. Journal of Material Processing Technology,1992(35):371-383
[13]解卓明.四锤头精锻机国产化的初探[J].锻压机械,1995(5)：41-42
[14]解卓明.四锤头精锻机研发工作的现状调查[J].大连铁道学院,锻压技术,2004(1)：21-23
[15]李艳萍.车轴径向锻造过程分析[J].锻压设备与制造技术,2007(1)：31-33
[16]王振范,胡宗式.径向锻造终锻过程的流函数法解析[J].东北大学学报,1994,15(1)：35-39
[17]董节功,周旭东,朱锦洪等.径向锻造三维成形锻透性的数值模拟[J].机械工程材料,2007,31(3)：76-78
[18]Liu Lili. Study of residual stress in the barrel process by the radial forging[J]. The Second International Conference on Information and Computing Science,2009:131-134
[19]韩星会.轴类零件径向锻造压入量研究[J].锻压设备与制造技术,2006(6)：75-78
[20]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[J].兵工学报,2009,30(8)：1098-1102
[21]G.D. Lahoti, T. Altan. Analysis and optimization of the radial forging process for manufacturing gun barrels[J]. Journal of Engineering for Industry,1976(1):265-271
[22]A. Ghaei, M.R. Movahhedy, A.Karimi Taheri. Study of the effects of die geometry on deformation in the radial forging process[J]. Journal of Materials Processing Technology, 2005(170):156-163
[23]A. Ghaei, A.Karimi Taheri, M.R. Movahhedy. A new upper bound solution for analysis of the radial forging process [J]. International Journal of Mechanical Sciences, 2006(48):1264-1272
[24]Sogawa S, Suzuki Y, Uehara N. Temperature transition and deformation process of inconel 718 during rotary forging[R]. Daido steel company, Japan,1990:1-10
[25]Domblesky JP, Shivpuri R. Development and validation of a finite element model for multiple-pass radial forging[J]. Journal of Material Processing and Technology,1995(55): 432-441
[26]A.Ghaei, M.R.Movahhedy, A.Karimi Taheri. Finite element modeling simulation of radial forging tubes without mandrel[J]. Materials and Design,2008(29):867-872
[27]Su-Hai Hsiang. Investigation of the influence of various process parameters on the radial forging processes by the finite element method(FEM)[J]. The International Journal of Advanced Manufacturing Technology,2004(23):627-635
[28]A. Ameli, M.R. Movahhedy. A parametric study on residual stresses and forging load in cold radial forging process [J]. The International Journal of Advanced Manufacturing Technology,2007(33):7-17
[29]A. Ameli, M.R. Movahhedy. Die design for the radial forging process using 3D FEM[J]. Journal of Materials Processing Technology,2007(182):534-539
[30]Stokes M, Ed. Managing Engineering Knowledge-MOKA:Methodology for Knowledge Based Engineering Applications[C], ASME Press,2001.
[31]Andreasen M.. Integrated product development[C]. Springer Verlag, Berlin.1987.
[32]Howard C..The virtual engineer,21st Century Project Development[J].Society of Manufacturing Engineers,1998:491-495
[33]J. Kulon, D.J.Mynors, P. Broomhead. A knowledge-based engineering design tool for metal forging[J]. Journal of Materials Processing Technology,2006(177):331-335
[34]Jie Hu, Yinghong Peng, Dayong Li, Jilong Yin. Robust optimization based on knowledge discovery from metal forming simulation[J]. Journal of Materials Processing Technology,2007:698-701
[35]张胜兰,郑冬黎,郝琪.基于HyperWorks的机构优化设计技术[M].机械工业出 版社,2007
[36]Zhang Rui. Finite element analysis based on Proe, Hypermesh and Ansys[C].2008 International Conference on Computer Science and Software Engineering,2008:622-625
[37]Fang Liu, Guang Meng, Mei Zhao. Experimental and numerical analysis of BGA lead-free solder joint reliability under board-level drop impact[J]. Microelectronics Reliability, 2009(49):79-85
[38]Rajesh Kalavalapally, Ravi Penmetsa, Ramana Grandhi. Configuration design of a lightweight torpedo subjected to an underwater explosion[J]. International Journal of Impact Engineering,2009(36):343-351
[39]Cato Dorum, Odd S.Hopperstad, Magnus Langseth. Numerical modeling of the crashworthiness of thin-walled cast magnesium components[G]. ABAQUS Users' Conference,2006:203-214
[40]Stoker H.C. Developments of the arbitrary lagrangian-eulerian method in non-linear solid mechanics[C]. Applications to Forming Processes. Eindhoven, Technische Universiteit Eindhoven,1999
[41]王跃先,陈军,阮雪榆.ALE有限元方法在金属塑性加工中的应用[J].模具技术,2001(3)：1-4
[42]ABAQUS/CAE User's Manual.18.5
[43]王旭成.有限单元法[M].北京：清华大学出版社,2003
[44]王旭成,邵敏.有限单元法基本原理和数值方法[M].清华大学出版社,1997
[45]朱伯芳.有限单元法原理和应用[M].水利电力出版社,1979(3)：5-15
[46]曹金凤,石亦平.ABAQUS有限元分析常见问题解答[M].机械工业出版社,2009
[47]庄茁.ABAQUS非线性有限元分析事例[M].科学出版社,2005(1)：1-4
[48]曹文君.知识库系统原理及其应用[M].复旦大学出版社,1995(8)：11-17
[49]娄臻亮,赵震等.工程设计KBE系统(1)：概述[J].机械科学与技术,2001(5)：169-171
[50]苑伟政,杨玉起.宇航难加工材料切削加工专家系统[J].航空工艺技术,1994(5)：21-23
[51]庞思勤,张启元,于启勋.硬质合金刀具实用专家系统结构分析[J].北京理工大学博士论文,2000
[52]陈统坚,彭冠,张俊.铣削加工过程多目标优化专家系统[J].机械工程师,1998(1)：5-6
[53]邹本清,周洪玉,郑敏利.刀片槽型CAD模块的设计与实现[J].哈尔滨理工大学学报,2000(2)：42-45
[54]毛用宁.基于知识的冲压工艺设计决策系统关键技术研究[D].上海交通大学硕士学位论文,2003
[55]赵震.面向创新设计理论体系的智能冲压工艺设计KBE技术研究[D].上海交通大学博士学位论文,2002
[56]陆汝钤.世纪之交的知识工程与知识科学[M].清华大学出版社,2001(9)：315-328
[57]蒋占四,陈立平,罗年猛.最近邻事例检索相似度分析[J].计算机集成制造系统,2007(6)：1165-1168
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