矩形钢丝成形工艺及优化研究
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摘要
异形钢丝在纺织、汽车、机械等方面有广泛的应用。矩形钢丝是异形钢丝的一种,传统的成形方法是采用固定模拉拔成形矩形钢丝,但成形时存在如周边圆角充不满,模具周边磨损不均匀导致模具寿命低等问题,很难实现大批量生产。本文以具体钢丝产品为研究对象,主要研究内容如下:
首先,研究了现有矩形钢丝成形方法的特点,成形过程的变形特征,分析了工艺参数对成形的影响,在此基础上提出了辊拉组合法成形的工艺方案。
其次,以材料为Q195,尺寸为2.3㎜×4.8㎜的矩形钢丝为研究对象,根据有限元理论,建立矩形钢丝拉拔成形三维有限元模型,并利用H.G公式验证了模型的正确性。
再其次,利用模型对辊拉组合成形进行了模拟,分析了成形过程中金属的流动特点和应力应变分布规律,验证了辊拉组合法成形工艺方案的可行性。
最后,采用正交试验设计方法分析了工艺参数对辊拉组合成形过程中影响,并对试验结果进行极差分析,得到最优化的工艺参数组合。
结果表明,对于材料为Q195,尺寸为2.3㎜×4.8㎜的矩形钢丝通过辊拉组合成形,可使钢丝的圆角半径最小达到0.17㎜,满足产品的使用要求,并且模具的磨损量小,具有较高的模具寿命。辊拉组合法成形对其它异型钢丝成形具有一定的借鉴作用。
Special-shaped wire is widely applied in the textile, automobile and machinery. Rectangular wire is a kind of it, which is shaped by die drawing traditionally. However, there are many problems when drawing it, such as fillet incomplete filling and nonhomogeneous wear of the die that reduces the life of die, thus it is hard to realize the mass production. In this paper, specified wire is regarded as the research object, and main studies are as follows:
Firstly, forming characteristics of the existing methods and the deformation features of forming process are studied, and the effect of process parameters on shaping is analyzed. The combination method is brought forward to drawing rectangular wire on the basis.
Secondly, taking rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜ as the research object, and three-dimensional finite element modeling of drawing is established according to the finite element theory. The correctness of the model is confirmed by H.G formula.
Thirdly, the forming process with combination method is simulated by the finite element model and metal flow characteristics and the law of stress and strain distribution are studied. It is verified that it is available to shape rectangular wire with combination method.
Last, orthogonal experiment design method is used to analyze the effect of process parameters to forming course, and the optimized combination of process parameters are obtained by employing range analysis to analyze the simulation results.
The results show that, rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜, it is able to acquire the minimum radius of fillet 0.17㎜ with combination method. Meanwhile, it can also meet the requests for utilization and the life of die is longer due to little wear. Combination method has some for helpful references to shaping other special-shaped wire.
首先,研究了现有矩形钢丝成形方法的特点,成形过程的变形特征,分析了工艺参数对成形的影响,在此基础上提出了辊拉组合法成形的工艺方案。
其次,以材料为Q195,尺寸为2.3㎜×4.8㎜的矩形钢丝为研究对象,根据有限元理论,建立矩形钢丝拉拔成形三维有限元模型,并利用H.G公式验证了模型的正确性。
再其次,利用模型对辊拉组合成形进行了模拟,分析了成形过程中金属的流动特点和应力应变分布规律,验证了辊拉组合法成形工艺方案的可行性。
最后,采用正交试验设计方法分析了工艺参数对辊拉组合成形过程中影响,并对试验结果进行极差分析,得到最优化的工艺参数组合。
结果表明,对于材料为Q195,尺寸为2.3㎜×4.8㎜的矩形钢丝通过辊拉组合成形,可使钢丝的圆角半径最小达到0.17㎜,满足产品的使用要求,并且模具的磨损量小,具有较高的模具寿命。辊拉组合法成形对其它异型钢丝成形具有一定的借鉴作用。
Special-shaped wire is widely applied in the textile, automobile and machinery. Rectangular wire is a kind of it, which is shaped by die drawing traditionally. However, there are many problems when drawing it, such as fillet incomplete filling and nonhomogeneous wear of the die that reduces the life of die, thus it is hard to realize the mass production. In this paper, specified wire is regarded as the research object, and main studies are as follows:
Firstly, forming characteristics of the existing methods and the deformation features of forming process are studied, and the effect of process parameters on shaping is analyzed. The combination method is brought forward to drawing rectangular wire on the basis.
Secondly, taking rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜ as the research object, and three-dimensional finite element modeling of drawing is established according to the finite element theory. The correctness of the model is confirmed by H.G formula.
Thirdly, the forming process with combination method is simulated by the finite element model and metal flow characteristics and the law of stress and strain distribution are studied. It is verified that it is available to shape rectangular wire with combination method.
Last, orthogonal experiment design method is used to analyze the effect of process parameters to forming course, and the optimized combination of process parameters are obtained by employing range analysis to analyze the simulation results.
The results show that, rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜, it is able to acquire the minimum radius of fillet 0.17㎜ with combination method. Meanwhile, it can also meet the requests for utilization and the life of die is longer due to little wear. Combination method has some for helpful references to shaping other special-shaped wire.
引文
[1]何吉林.钢丝生产[M].北京:兵器工业出版社,2003
[2]岳志军,康武军,李二真.异型钢丝的生产[J].金属制品,2001,27(4):20~22
[3]安顺达.棒、线材生产新工艺、新技术与产品质量控制实用手册[M].北京:北京冶金出版社,2006
[4]武大鹏,陈文琳,张文超等.矩形钢丝成形有限元模拟及工艺参数优化[J].金属制品,2010,36(1):34~41
[5]戴宝昌.重要用途线材制品生产新技术[M].北京:冶金工业出版社,2001
[6]徐效谦,阴绍芬.特殊钢钢丝[M].北京:冶金工业出版社,2005.
[7]沈献民.感应加热油回火钢丝生产技术现状及发展方向[J].金属制品,2008,34(4):1~4
[8] B.L. Juneja, R. PraKash.An analysis for drawing and extrusion of polygonal sections [J].International Journal of Machine Tool Design and Research, 1975 (15):1~30
[9] R. PraKash, Q.M. Khan. An analysis of plastic flow through polygonal converging dies with generalized boundaries of the zone of plastic deformation [J].International Journal of Machine Tool Design and Research, 1979 (19):1~19
[10] BB. Basily, DH. Sansome.Some theoretical considerations for the direct drawing of section rod from round bar [J].International Journal of Mechanical Sciences, 1976 (18):201~208
[11] JS. Gunasekera, S. Hoshino.Analysis of extrusion or drawing of polygonal sections through straightly converging dies [J] . American Society of Mechanical Engineers, 1982 (14):38~45
[12] JS. Gunasekera, S. Hoshino.Analysis of extrusion of polygonal sections through streamlined dies [J].American Society of Mechanical Engineers, 1985 (107):229~233
[13] CR. Boer, Jr. WD. Webster.Direct upper-bound solution and finite element approach to round-to-square drawing [J].American Society of Mechanical Engineers, 1985 (107):254~260
[14] M. BrücKer, D. Keller, J. Reissner.Computer-aided drawing of profiles from round and square bar [J].Annals of the CIRP, 1988 (37):247~250
[15] K.Yoshida, S.Yamada, S. Suzu.Mechanics of deformation in round-to-hexagon drawing by FEM [J].Process of Japan Society for Technology Plasticity, 1994(45):161~164
[16] H.C. Kim, Y.C. Kim, Y. Choi, et al.A study on the drawing process of square rod from round bar by using the rigid-plastic finite element method [J].Korean Society for Precision Engineering, 1998 (15):145~151
[17] H.C. Kim, Y. Choi, B.M. Kim.Three dimensional rigid-plastic finite element analysis of non-steady-state shaped drawing process [J].International Journal of Machine Tools and Manufacture, 1999 (39):1135~1155
[18] YC. Kim, BM. Kim.A study on the corner filling in the drawing of a rectangular rod from a round bar [J].International Journal of Machine Tools and Manufacture, 2000 (40):2099~2117
[19] S Laila, Bayoumi.Round-to-square section drawing through flat idle rolls [J]. International Journal of Mechanical Sciences, 1999 (41):1323~1338
[20] K.L. Wang.Design and analysis of direct cold drawing of section rods using semi-analytical finite element method [J] . Technical Paper-Society of Manufacturing Engineers, 1999 (99):1~6
[21] K.L. Wang, Vasilis Argyropoulos.Design and analysis of direct cold drawing of section rods through a single die [J].Journal of Materials Processing Technology, 2005 (166):345~358
[22]郑宝龙,李连诗.滚模拉拔异型丝新工艺[J].金属制品,1994,16(2):158~161
[23]郑宝龙,朱为昌,徐言东.辊模拉拔技术及其应用[J].金属成形工艺,1996,14(1):43~46
[24]张静.异型丝辊拔过程中宽展的研究[J].沈阳工业学院学报,1992,11(4):41~46
[25]汪洪明,吴武楠,孟宪德等.滚拔工艺生产卡环异型丝的研制[J].大连特殊钢,1995 (1):29~34
[26]周林,雷霆,方树铭等.精密异型钛材辊模拉扎加工工艺研究[J].稀有金属,2007,31 (3):122~125
[27]宋清华,王伯健.平辊压扁轧制圆钢丝工艺的研究动态[J].材料导报网刊,2007,2(1):41~45
[28]师晓莉,宋清华,王伯健等.平辊压扁轧制纺织器材用超窄钢带的工艺研究[J].纺织器材,2007,34(2):68~73
[29]李窘,方威.不锈钢异型丝冷拔生产工艺研究[J].金属制品,1998,24(1):13~16
[30]张玉新,李勇,郝用兴等.Y型辊模拉拔工艺的三维数值模拟研究[J].锻压技术,2007,32(1):46~49
[31]王勖成,邵敏.有限单元法基本原理与数值方法(第二版) [M].北京:清华大学出版社,1988
[32]黄义,张引科.张量及其在连续介质力学中的应用[M].北京:冶金工业出版社,2002
[33]吕洪生,曾新吾.连续介质力学[M].长沙:国防科技大学出版社,1999
[34]冯振兴.连续统力学及其数值模拟[M].武汉:武汉大学出版社,1996
[35]殷有泉.固体力学非线性有限元引论[M].北京:北京大学出版社,1987
[36]陈如欣,胡忠民.塑性有限元法及其在金属成形中的应用[M].四川:重庆大学出版社,1989
[37]陈忠家.厚板热弯曲成形的刚粘塑性有限元数值模拟研究[D].合肥工业大学硕士论文,2000
[38]谢水生,王祖唐.金属塑性成形工步的有限元数值模拟[M].北京:冶金工业出版社,1997
[39]孟凡中.弹塑性有限变形理论和有限元方法[M].北京:清华大学出版社,1985
[40]谢水生,李雷.金属塑性成形的有限元模拟技术及应用[M].北京:科技出版社,2008
[41]王祖城,汪家才.弹性和塑性理论及有限单元法[M].北京:冶金工业出版社,1983
[42]郑宝龙,朱为昌,刘希和.辊模拉拔运动学分析[J].金属制品,1995,22(5):10~13
[43]吕立华.金属塑性变形与轧制原理[M].北京:化学工业出版社,2007
[44]李生智.金属压力加工概论[M].北京:冶金工业出版社,2005
[45]温景林,丁桦,曹荣福等.有色金属挤压与拉拔技术[M].北京:化学工业出版社,2007
[46]马怀宪.金属塑性加工学——挤压、拉拔与管材冷轧[M].北京:冶金工业出版社,2006
[47]温景林.金属挤压与拉拔工艺学[M].沈阳:东北大学出版社,2003
[48]陈献廷.硬质合金使用手册[M].北京:冶金工业出版社,1986
[49]甘晓明.聚晶金刚石拉丝模具孔型结构分析[J].金刚石与磨料磨具工程,2005 (2):50~52
[50]胡东福,龚洪海.辊拉异型钢丝压扁宽展计算公式推导[J].金属制品,1990,16(1):47~49
[51]董德元.轧制计算机辅助工程[M].北京:冶金工业出版社,1992
[52]陈魁.试验设计与分析[M].北京:清华大学出版社,2005
[53]李云雁,胡传荣.试验设计与数据处理[M].北京:化学工业出版社,2008
[2]岳志军,康武军,李二真.异型钢丝的生产[J].金属制品,2001,27(4):20~22
[3]安顺达.棒、线材生产新工艺、新技术与产品质量控制实用手册[M].北京:北京冶金出版社,2006
[4]武大鹏,陈文琳,张文超等.矩形钢丝成形有限元模拟及工艺参数优化[J].金属制品,2010,36(1):34~41
[5]戴宝昌.重要用途线材制品生产新技术[M].北京:冶金工业出版社,2001
[6]徐效谦,阴绍芬.特殊钢钢丝[M].北京:冶金工业出版社,2005.
[7]沈献民.感应加热油回火钢丝生产技术现状及发展方向[J].金属制品,2008,34(4):1~4
[8] B.L. Juneja, R. PraKash.An analysis for drawing and extrusion of polygonal sections [J].International Journal of Machine Tool Design and Research, 1975 (15):1~30
[9] R. PraKash, Q.M. Khan. An analysis of plastic flow through polygonal converging dies with generalized boundaries of the zone of plastic deformation [J].International Journal of Machine Tool Design and Research, 1979 (19):1~19
[10] BB. Basily, DH. Sansome.Some theoretical considerations for the direct drawing of section rod from round bar [J].International Journal of Mechanical Sciences, 1976 (18):201~208
[11] JS. Gunasekera, S. Hoshino.Analysis of extrusion or drawing of polygonal sections through straightly converging dies [J] . American Society of Mechanical Engineers, 1982 (14):38~45
[12] JS. Gunasekera, S. Hoshino.Analysis of extrusion of polygonal sections through streamlined dies [J].American Society of Mechanical Engineers, 1985 (107):229~233
[13] CR. Boer, Jr. WD. Webster.Direct upper-bound solution and finite element approach to round-to-square drawing [J].American Society of Mechanical Engineers, 1985 (107):254~260
[14] M. BrücKer, D. Keller, J. Reissner.Computer-aided drawing of profiles from round and square bar [J].Annals of the CIRP, 1988 (37):247~250
[15] K.Yoshida, S.Yamada, S. Suzu.Mechanics of deformation in round-to-hexagon drawing by FEM [J].Process of Japan Society for Technology Plasticity, 1994(45):161~164
[16] H.C. Kim, Y.C. Kim, Y. Choi, et al.A study on the drawing process of square rod from round bar by using the rigid-plastic finite element method [J].Korean Society for Precision Engineering, 1998 (15):145~151
[17] H.C. Kim, Y. Choi, B.M. Kim.Three dimensional rigid-plastic finite element analysis of non-steady-state shaped drawing process [J].International Journal of Machine Tools and Manufacture, 1999 (39):1135~1155
[18] YC. Kim, BM. Kim.A study on the corner filling in the drawing of a rectangular rod from a round bar [J].International Journal of Machine Tools and Manufacture, 2000 (40):2099~2117
[19] S Laila, Bayoumi.Round-to-square section drawing through flat idle rolls [J]. International Journal of Mechanical Sciences, 1999 (41):1323~1338
[20] K.L. Wang.Design and analysis of direct cold drawing of section rods using semi-analytical finite element method [J] . Technical Paper-Society of Manufacturing Engineers, 1999 (99):1~6
[21] K.L. Wang, Vasilis Argyropoulos.Design and analysis of direct cold drawing of section rods through a single die [J].Journal of Materials Processing Technology, 2005 (166):345~358
[22]郑宝龙,李连诗.滚模拉拔异型丝新工艺[J].金属制品,1994,16(2):158~161
[23]郑宝龙,朱为昌,徐言东.辊模拉拔技术及其应用[J].金属成形工艺,1996,14(1):43~46
[24]张静.异型丝辊拔过程中宽展的研究[J].沈阳工业学院学报,1992,11(4):41~46
[25]汪洪明,吴武楠,孟宪德等.滚拔工艺生产卡环异型丝的研制[J].大连特殊钢,1995 (1):29~34
[26]周林,雷霆,方树铭等.精密异型钛材辊模拉扎加工工艺研究[J].稀有金属,2007,31 (3):122~125
[27]宋清华,王伯健.平辊压扁轧制圆钢丝工艺的研究动态[J].材料导报网刊,2007,2(1):41~45
[28]师晓莉,宋清华,王伯健等.平辊压扁轧制纺织器材用超窄钢带的工艺研究[J].纺织器材,2007,34(2):68~73
[29]李窘,方威.不锈钢异型丝冷拔生产工艺研究[J].金属制品,1998,24(1):13~16
[30]张玉新,李勇,郝用兴等.Y型辊模拉拔工艺的三维数值模拟研究[J].锻压技术,2007,32(1):46~49
[31]王勖成,邵敏.有限单元法基本原理与数值方法(第二版) [M].北京:清华大学出版社,1988
[32]黄义,张引科.张量及其在连续介质力学中的应用[M].北京:冶金工业出版社,2002
[33]吕洪生,曾新吾.连续介质力学[M].长沙:国防科技大学出版社,1999
[34]冯振兴.连续统力学及其数值模拟[M].武汉:武汉大学出版社,1996
[35]殷有泉.固体力学非线性有限元引论[M].北京:北京大学出版社,1987
[36]陈如欣,胡忠民.塑性有限元法及其在金属成形中的应用[M].四川:重庆大学出版社,1989
[37]陈忠家.厚板热弯曲成形的刚粘塑性有限元数值模拟研究[D].合肥工业大学硕士论文,2000
[38]谢水生,王祖唐.金属塑性成形工步的有限元数值模拟[M].北京:冶金工业出版社,1997
[39]孟凡中.弹塑性有限变形理论和有限元方法[M].北京:清华大学出版社,1985
[40]谢水生,李雷.金属塑性成形的有限元模拟技术及应用[M].北京:科技出版社,2008
[41]王祖城,汪家才.弹性和塑性理论及有限单元法[M].北京:冶金工业出版社,1983
[42]郑宝龙,朱为昌,刘希和.辊模拉拔运动学分析[J].金属制品,1995,22(5):10~13
[43]吕立华.金属塑性变形与轧制原理[M].北京:化学工业出版社,2007
[44]李生智.金属压力加工概论[M].北京:冶金工业出版社,2005
[45]温景林,丁桦,曹荣福等.有色金属挤压与拉拔技术[M].北京:化学工业出版社,2007
[46]马怀宪.金属塑性加工学——挤压、拉拔与管材冷轧[M].北京:冶金工业出版社,2006
[47]温景林.金属挤压与拉拔工艺学[M].沈阳:东北大学出版社,2003
[48]陈献廷.硬质合金使用手册[M].北京:冶金工业出版社,1986
[49]甘晓明.聚晶金刚石拉丝模具孔型结构分析[J].金刚石与磨料磨具工程,2005 (2):50~52
[50]胡东福,龚洪海.辊拉异型钢丝压扁宽展计算公式推导[J].金属制品,1990,16(1):47~49
[51]董德元.轧制计算机辅助工程[M].北京:冶金工业出版社,1992
[52]陈魁.试验设计与分析[M].北京:清华大学出版社,2005
[53]李云雁,胡传荣.试验设计与数据处理[M].北京:化学工业出版社,2008