弹膛精锻加工过程数值模拟及工艺参数影响研究
摘要
枪管是一种厚壁空心管件，由线膛、弹膛、外表面三部分组成。在现行枪管加工工艺中，基本采取径向锻造线膛，机加工外表面与弹膛，生产效率低下，机加工出的弹膛部分组织细密性、耐磨抗蚀差，表面粗糙度难以保证。
在弹膛的锻压过程中，其可行性、成形质量(含充满成形、折叠、组织缺陷等)、材料利用率以及如何降低锻压力、提高模具使用寿命等，都是在制定成形工艺时必须重点考虑的。本文针对弹膛成形中的锻压加工中的以上几点关键技术，基于有限元刚塑性理论使用Ls-dyna对其成形过程进行模拟，进行了如下工作：
(1)分析了摩擦系数、轴向进给对于锻压力、应变分布的影响，降低了锻压力、改善了应变分布情况。
(2)分析了坯料外径对于成形质量、锻压力、锻透程度、应变分布的影响，合理选择了坯料外径，很好地解决了充满成形问题，降低了锻压力、改善了应变分布情况。
(3)分析了弹膛内锥面的高度及长度对成形情况的影响进行了分析，综合考虑在不同高度及长度下的成形及应变分布情况，得出了在成形加工中可以实现的极限高度及长度，为指导相关设计打下了坚实的基础。
Gun barrel is a thick and hollow part which is composed with three characteristic surface: line chamber, chamber, outside surface.
In the currently producing process, line chamber is generally produced by radial forging; the two other characters are made with machining. The shortcoming of machining is that the productivity is very low and it is very hard to guarantee the tolerance of inner radius and surface roughness of the chamber.
The feasibility, stability, quality of forming(including brimming forming, replicate and organize disfigurement), material utilize efficiency and how to reduce load, how to improve life-span of mould are all emphasized when we work out forming techniques. In this paper, several key techniques are simulated with software Ls-dyna:
(1)Analyze the change of load and strain distribute in different friction and feed; reduce the load and improve the uniformity of strain distribute.
(2)Analyze the change of load, quality of forming, strain distribute in different diameter, improve the uniformity of strain distribution and the quality of forming, resolve the brimming forming by choosing a reasonable diameter.
(3)Research the chamber length and height which will effect the quality of forming, find out the maximal height and minimum length which can be obtained in forging and will guide us in design.
在弹膛的锻压过程中，其可行性、成形质量(含充满成形、折叠、组织缺陷等)、材料利用率以及如何降低锻压力、提高模具使用寿命等，都是在制定成形工艺时必须重点考虑的。本文针对弹膛成形中的锻压加工中的以上几点关键技术，基于有限元刚塑性理论使用Ls-dyna对其成形过程进行模拟，进行了如下工作：
(1)分析了摩擦系数、轴向进给对于锻压力、应变分布的影响，降低了锻压力、改善了应变分布情况。
(2)分析了坯料外径对于成形质量、锻压力、锻透程度、应变分布的影响，合理选择了坯料外径，很好地解决了充满成形问题，降低了锻压力、改善了应变分布情况。
(3)分析了弹膛内锥面的高度及长度对成形情况的影响进行了分析，综合考虑在不同高度及长度下的成形及应变分布情况，得出了在成形加工中可以实现的极限高度及长度，为指导相关设计打下了坚实的基础。
Gun barrel is a thick and hollow part which is composed with three characteristic surface: line chamber, chamber, outside surface.
In the currently producing process, line chamber is generally produced by radial forging; the two other characters are made with machining. The shortcoming of machining is that the productivity is very low and it is very hard to guarantee the tolerance of inner radius and surface roughness of the chamber.
The feasibility, stability, quality of forming(including brimming forming, replicate and organize disfigurement), material utilize efficiency and how to reduce load, how to improve life-span of mould are all emphasized when we work out forming techniques. In this paper, several key techniques are simulated with software Ls-dyna:
(1)Analyze the change of load and strain distribute in different friction and feed; reduce the load and improve the uniformity of strain distribute.
(2)Analyze the change of load, quality of forming, strain distribute in different diameter, improve the uniformity of strain distribution and the quality of forming, resolve the brimming forming by choosing a reasonable diameter.
(3)Research the chamber length and height which will effect the quality of forming, find out the maximal height and minimum length which can be obtained in forging and will guide us in design.
引文
[1] 105教研室．枪炮构造讲义．华东工程学院．1975
[2] A．A．勃拉贡拉沃夫．枪管制造．北京：国防工业出版社．1956
[3] M. Yoshino, T. shirkashi & J. Eto. Study on mesoplasticity Recrystallization process by mesoplasticity EM. 1998.06
[4] G.J. Li and S. Kobayashi. Rigid-plastic Finite Element Analysis of Plane strain Rolling. Trans, ASME, J. Eng. lnd., 1982: 104
[5] S. Kobayashi. A Review on the finite Element Method and Metal Forming Process Modeling. J. Appl. Metal Working, 1982, (2): 163
[6] G.J. Li and S. Kobayashi. Spread Analysis in Rolling By Rigid-plastic Finite Element Method. In: J.F.T. and I. Pittman. Eds. Numerical Method in Industrial Forming Processes, Swansea, UK, Pineridge Press, 1982: 777-786
[7] S. Kobayashi. Thermo-viscoplastic Analysis of Metal Forming Problems By the Finite Element Method. In: J.F.T. and I. Pittman. Eds. Numerical Method in Industrial Forming Processes, Swansea, UK, Pineridge Press, 1982: 17-25
[8] S.I. Oh, J.J. Pak, S. Kobayashi and T. Alan. Application of FEM Modeling to Simulate Metal Flow in Forging a Titanium Alloy Engine Disk. Trans. ASME. J. Eng. Ind. 1983: 105-251
[9] J.X. Sun and S. Kobayashi. Analysis of Block Compression with Simplified Three-dimensional Element. Adv. Tech. Plasticity-Proc. 1st ICTP. TOKYO, 1984, (2): 1027-1034
[10] S. Kobayashi. The Role of Finite Element Method in Metal Forming Technology. Adv. Tech. Plasticity-Proc. 1st ICTP. TOKYO, 1984, (2)1035-1040
[11] S. Kobayashi. Thirty—four Years at Berkeley. Adv. Tech. Plasticity-Proc. 1st ICTP. TOKYO, 1990, (4)1637
[12] 王梦寒．F738壳体成形工艺数值模拟仿真及优化．重庆大学硕士学位论文．2002
[13] 白金泽．LS-DYNA3D理论基础与实例分析．北京：科学出版社，2005
[14] 于开平，周传月，谭惠丰．HyperMesh从入门到精通．北京：科学出版社，2005
[15] 赵海鸥．LS-DYNA动力分析指南．北京：兵器工业出版社，2003
[16] 彭颖红．金属塑性成形仿真技术．上海：上海交通大学出版社，1998
[17] 王勖成，邵敏．有限单元法基本原理和数值方法．北京：清华大学出版社，1997
[18] 熊庆华，王梦寒，周杰．TC4钛合金管径向温锻成形工艺仿真．锻压装备与制造技术，2005(3)50-52
[19] 吕炎．精密塑性体积成形技术．北京：国防工业出版社．2003
[20] 杨振恒．锻造工艺学．西安：西北工业大学出版社．1986
[21] 韩育礼．枪炮身管设计原理．北京：国防工业出版社．1982
[22] 南京理工大学105教研室．枪械构造讲义．南京理工大学，1975
[23] 张玉新，钟毅，王华昆，李勇．塑性成形中的六面体网格划分与重划分技术．锻压技术，2004(6)33-61
[24] 翟福宝．有限元模拟在金属塑性成形中的应用．锻压机械，2000(3)46-48
[25] 解卓明．四锤头精锻机研发工作的现状调查．锻压技术，2004(1)47-48
[26] 南京理工大学105教研室．枪械设计原理．南京理工大学，1979
[27] 刘建生，陈慧琴，郭晓霞．金属塑性加工有限元模拟技术与应用．北京：冶金工业出版，2D03
[28] 王亚平．自动武器数值仿真技术及其应用．南京理工大学博士论文，2003
[29] 田福祥．锤体精锻新工艺与预锻模设计．塑性加工技术，2003(5)37-39
[30] 洪深泽．挤压工艺及模具设计．北京：机械工业出版社，1996
[31] F H Osman, E Meerygold. Effect of differential heating on modes of plastic deformation in forging process, Conference on technology of plasticity, Ohio, USA, 1997
[32] 胡亚民，车路长．精锻成形技术现状及其发展．锻压机械，1996(3)6-9
[33] 赵新海．金属体积成形预成形设计的现状及发展．塑性工程学报，2000(3)1-6
[34] 徐秉业．弹塑性力学及其应用．北京：机械工业出版社，1984
[35] R．A．C．斯莱特著，王仲仁译．工程塑性理论及其在金属成形中的应用．北京：机械工业出版社，1983
[36] 王仲仁．锻压手册(第一卷)．北京：机械工业出版社，1993
[37] 王大年．金属塑性成形原理．北京：机械工业出版社，1982
[38] Klong. Some aspects of development of cold forging to a high-tech precison technology. Jou Master pro tech, 1992, 35: 245～247
[39] Doge E, ect. Condition for a structured layout of precision forging. Jou Master pro tech, 1946, 46: 41～45
[40] J.H. Argyris, J.S. Doltsinis, J. Luginsland. Three-dimensional Thermomechanial Analysis of Metal Forming Processes. Int. Simulation of Metal Forming Processes by the Finite Element Method, Proceedings of the International Workshop, Berlin: Springer Press 1986: 125～169
[41] 陈如欣，胡中民．塑性有限元法及其在金属成形中的应用．重庆：重庆大学出版社，1989
[42] 吕丽萍．有限元法及其在锻压工程中的应用．西安：西北工业大学出版社，1989
[43] Kobayashi S, Oh S I, Altan T. Metal forming and finite-element method. Oxford University Press, 1989
[44] 刘庆斌，吴诗惇，孙胜．轴对称锻件预成形设计的新方法．热加工工艺，1992(5)：32-34
[45] 赵新海．基于有限元模拟的锻造过程优化设计方法研究．山东大学博士论文，2001
[46] 赵新海，马新武．锻造过程中变形均匀性的控制及模具优化设计．材料科学与工艺，1999：1-4
[47] 罗仁平．锻造过程预成形计算机辅助优化设计研究．上海交通大学博士论文，1999
[48] 沈阳市第一锻造厂编．精密锻轴工艺．北京：机械工业出版社 1955
[49] R.B. Douglas. The application of CAD/CAM techniques at Harland and Wolff. Computer Aided Designed1986
[50] 卓惠如．机枪枪管寿命预测技术-论文集．北京：中国兵器工业第二零八研究所，1996
[2] A．A．勃拉贡拉沃夫．枪管制造．北京：国防工业出版社．1956
[3] M. Yoshino, T. shirkashi & J. Eto. Study on mesoplasticity Recrystallization process by mesoplasticity EM. 1998.06
[4] G.J. Li and S. Kobayashi. Rigid-plastic Finite Element Analysis of Plane strain Rolling. Trans, ASME, J. Eng. lnd., 1982: 104
[5] S. Kobayashi. A Review on the finite Element Method and Metal Forming Process Modeling. J. Appl. Metal Working, 1982, (2): 163
[6] G.J. Li and S. Kobayashi. Spread Analysis in Rolling By Rigid-plastic Finite Element Method. In: J.F.T. and I. Pittman. Eds. Numerical Method in Industrial Forming Processes, Swansea, UK, Pineridge Press, 1982: 777-786
[7] S. Kobayashi. Thermo-viscoplastic Analysis of Metal Forming Problems By the Finite Element Method. In: J.F.T. and I. Pittman. Eds. Numerical Method in Industrial Forming Processes, Swansea, UK, Pineridge Press, 1982: 17-25
[8] S.I. Oh, J.J. Pak, S. Kobayashi and T. Alan. Application of FEM Modeling to Simulate Metal Flow in Forging a Titanium Alloy Engine Disk. Trans. ASME. J. Eng. Ind. 1983: 105-251
[9] J.X. Sun and S. Kobayashi. Analysis of Block Compression with Simplified Three-dimensional Element. Adv. Tech. Plasticity-Proc. 1st ICTP. TOKYO, 1984, (2): 1027-1034
[10] S. Kobayashi. The Role of Finite Element Method in Metal Forming Technology. Adv. Tech. Plasticity-Proc. 1st ICTP. TOKYO, 1984, (2)1035-1040
[11] S. Kobayashi. Thirty—four Years at Berkeley. Adv. Tech. Plasticity-Proc. 1st ICTP. TOKYO, 1990, (4)1637
[12] 王梦寒．F738壳体成形工艺数值模拟仿真及优化．重庆大学硕士学位论文．2002
[13] 白金泽．LS-DYNA3D理论基础与实例分析．北京：科学出版社，2005
[14] 于开平，周传月，谭惠丰．HyperMesh从入门到精通．北京：科学出版社，2005
[15] 赵海鸥．LS-DYNA动力分析指南．北京：兵器工业出版社，2003
[16] 彭颖红．金属塑性成形仿真技术．上海：上海交通大学出版社，1998
[17] 王勖成，邵敏．有限单元法基本原理和数值方法．北京：清华大学出版社，1997
[18] 熊庆华，王梦寒，周杰．TC4钛合金管径向温锻成形工艺仿真．锻压装备与制造技术，2005(3)50-52
[19] 吕炎．精密塑性体积成形技术．北京：国防工业出版社．2003
[20] 杨振恒．锻造工艺学．西安：西北工业大学出版社．1986
[21] 韩育礼．枪炮身管设计原理．北京：国防工业出版社．1982
[22] 南京理工大学105教研室．枪械构造讲义．南京理工大学，1975
[23] 张玉新，钟毅，王华昆，李勇．塑性成形中的六面体网格划分与重划分技术．锻压技术，2004(6)33-61
[24] 翟福宝．有限元模拟在金属塑性成形中的应用．锻压机械，2000(3)46-48
[25] 解卓明．四锤头精锻机研发工作的现状调查．锻压技术，2004(1)47-48
[26] 南京理工大学105教研室．枪械设计原理．南京理工大学，1979
[27] 刘建生，陈慧琴，郭晓霞．金属塑性加工有限元模拟技术与应用．北京：冶金工业出版，2D03
[28] 王亚平．自动武器数值仿真技术及其应用．南京理工大学博士论文，2003
[29] 田福祥．锤体精锻新工艺与预锻模设计．塑性加工技术，2003(5)37-39
[30] 洪深泽．挤压工艺及模具设计．北京：机械工业出版社，1996
[31] F H Osman, E Meerygold. Effect of differential heating on modes of plastic deformation in forging process, Conference on technology of plasticity, Ohio, USA, 1997
[32] 胡亚民，车路长．精锻成形技术现状及其发展．锻压机械，1996(3)6-9
[33] 赵新海．金属体积成形预成形设计的现状及发展．塑性工程学报，2000(3)1-6
[34] 徐秉业．弹塑性力学及其应用．北京：机械工业出版社，1984
[35] R．A．C．斯莱特著，王仲仁译．工程塑性理论及其在金属成形中的应用．北京：机械工业出版社，1983
[36] 王仲仁．锻压手册(第一卷)．北京：机械工业出版社，1993
[37] 王大年．金属塑性成形原理．北京：机械工业出版社，1982
[38] Klong. Some aspects of development of cold forging to a high-tech precison technology. Jou Master pro tech, 1992, 35: 245～247
[39] Doge E, ect. Condition for a structured layout of precision forging. Jou Master pro tech, 1946, 46: 41～45
[40] J.H. Argyris, J.S. Doltsinis, J. Luginsland. Three-dimensional Thermomechanial Analysis of Metal Forming Processes. Int. Simulation of Metal Forming Processes by the Finite Element Method, Proceedings of the International Workshop, Berlin: Springer Press 1986: 125～169
[41] 陈如欣，胡中民．塑性有限元法及其在金属成形中的应用．重庆：重庆大学出版社，1989
[42] 吕丽萍．有限元法及其在锻压工程中的应用．西安：西北工业大学出版社，1989
[43] Kobayashi S, Oh S I, Altan T. Metal forming and finite-element method. Oxford University Press, 1989
[44] 刘庆斌，吴诗惇，孙胜．轴对称锻件预成形设计的新方法．热加工工艺，1992(5)：32-34
[45] 赵新海．基于有限元模拟的锻造过程优化设计方法研究．山东大学博士论文，2001
[46] 赵新海，马新武．锻造过程中变形均匀性的控制及模具优化设计．材料科学与工艺，1999：1-4
[47] 罗仁平．锻造过程预成形计算机辅助优化设计研究．上海交通大学博士论文，1999
[48] 沈阳市第一锻造厂编．精密锻轴工艺．北京：机械工业出版社 1955
[49] R.B. Douglas. The application of CAD/CAM techniques at Harland and Wolff. Computer Aided Designed1986
[50] 卓惠如．机枪枪管寿命预测技术-论文集．北京：中国兵器工业第二零八研究所，1996