花键管挤压成形规律研究
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摘要
花键主要用于联接轴和轴上零件(如齿轮、带轮)之间的周向固定并传递转矩,有的还能实现轴上零件的轴向固定或轴向滑动。内外空心花键管由于其截面形状的特殊性,轴向尺寸较长,且尺寸精度和表面质量要求较高,对成形工艺提出了更高的要求,因而其生产工艺不同于传统花键管的生产工艺。本文在研究国内外花键生产的基础上,对内外空心花键管的成形进行了工艺性分析,提出了花键管的冷挤压工艺。阐述了冷挤压工艺的特点,研究了影响花键管冷挤压件尺寸的主要因素。
利用三坐标仪测量花键管零件原型,应用大型造型软件UG完成了三坐标仪对空心花键管原型进行测量得到的点阵的处理,从而得到精确的零件原型尺寸,并利用测量结果进行实物的三维造型,得到内外空心花键管的几何模型
基于有限元理论,建立了花键管冷挤压成形过程的有限元分析模型。基于DEFORM—3D三维有限元模拟软件,应用三维刚塑性有限元算法对花键管冷挤压成形过程进行了模拟分析,得出变形中金属的流动状态和等效塑性应力应变分布规律,整个冷挤压变形结果用图形、曲线直观的显式出来,获得挤压成形金属变形规律
通过有限元模拟对花键管冷挤压工艺参数和模具结构进行了研究,分析了花键管冷挤压成型的金属变形规律,选择合理的管坯,优化了工艺参数和模具结构,确定了花键管冷挤压成形所需压力机。研究了主要因素,如摩擦和模锥角对成形载荷的影响。
结合冷挤压成形经验,参照模拟结果确定模具设计参数,完成凸凹模设计。将理论研究联系实际,在试验中测得花键管变形数据,得到花键管冷挤压成形中主要参数对成形过程的影响,及金属变形规律。
Spline is usually employed for circumferential orientation of part, such as gear and pulley, and torsion transmission, as well as axial orientation and axial motion, with the particular section, long axial length, high accuracy and high surface quality, the spline tube has more strict requirements for the plastic forming process which is different from the other traditional forming process. Based on the analysis to the current spline forming process at home and abroad, the spline tube forming process was studied and the cold extrusion process was suggested. The cold extrusion process was introduced and the influential factors are researched.The spline tube's three dimensional data was gained with the help of three dimensional measurement machine. By the treatment to the measurement data in UG software, the accurate spline tube model was made, as well as the real dimension.The finite element model was made by finite element theory, and the simulation analysis with the DEFORM-3D software came up with the metal flow status and equivalent plastic stress-strain curves which are visible and meaningful.Simulation research and optimization were made to the spline tube cold extrusion process parameters and die structure, the pre-part and cold extrusion mill for spline tube production was also designed and selected. The influence law of the main influential factors, such as friction coefficient and cone angle , on the forming force were studied.Combined with the spline tube cold extrusion experiments and the reference to the simulation results, the die parameters are designed for punch and matrix. By the employment of theory to experiment, the measurement data came up with the influential law of several main factors on cold extrusion forming and the metal forming rules.
利用三坐标仪测量花键管零件原型,应用大型造型软件UG完成了三坐标仪对空心花键管原型进行测量得到的点阵的处理,从而得到精确的零件原型尺寸,并利用测量结果进行实物的三维造型,得到内外空心花键管的几何模型
基于有限元理论,建立了花键管冷挤压成形过程的有限元分析模型。基于DEFORM—3D三维有限元模拟软件,应用三维刚塑性有限元算法对花键管冷挤压成形过程进行了模拟分析,得出变形中金属的流动状态和等效塑性应力应变分布规律,整个冷挤压变形结果用图形、曲线直观的显式出来,获得挤压成形金属变形规律
通过有限元模拟对花键管冷挤压工艺参数和模具结构进行了研究,分析了花键管冷挤压成型的金属变形规律,选择合理的管坯,优化了工艺参数和模具结构,确定了花键管冷挤压成形所需压力机。研究了主要因素,如摩擦和模锥角对成形载荷的影响。
结合冷挤压成形经验,参照模拟结果确定模具设计参数,完成凸凹模设计。将理论研究联系实际,在试验中测得花键管变形数据,得到花键管冷挤压成形中主要参数对成形过程的影响,及金属变形规律。
Spline is usually employed for circumferential orientation of part, such as gear and pulley, and torsion transmission, as well as axial orientation and axial motion, with the particular section, long axial length, high accuracy and high surface quality, the spline tube has more strict requirements for the plastic forming process which is different from the other traditional forming process. Based on the analysis to the current spline forming process at home and abroad, the spline tube forming process was studied and the cold extrusion process was suggested. The cold extrusion process was introduced and the influential factors are researched.The spline tube's three dimensional data was gained with the help of three dimensional measurement machine. By the treatment to the measurement data in UG software, the accurate spline tube model was made, as well as the real dimension.The finite element model was made by finite element theory, and the simulation analysis with the DEFORM-3D software came up with the metal flow status and equivalent plastic stress-strain curves which are visible and meaningful.Simulation research and optimization were made to the spline tube cold extrusion process parameters and die structure, the pre-part and cold extrusion mill for spline tube production was also designed and selected. The influence law of the main influential factors, such as friction coefficient and cone angle , on the forming force were studied.Combined with the spline tube cold extrusion experiments and the reference to the simulation results, the die parameters are designed for punch and matrix. By the employment of theory to experiment, the measurement data came up with the influential law of several main factors on cold extrusion forming and the metal forming rules.
引文
[1] 舒键.花键冷挤压技术获得突破.中国乡镇企业报.2002.9.9
[2] 易宏展,任运来,冯杨等.花键轴冷挤压成形应用.锻压机械.2002年第5期.2002,37(5)
[3] Zhang zhenchun, LiJun. Experimental Study on Open-die Cold Extrusion Forming Technique for Involute Spline Shafts. Chinese Journal of Mechnical Engineering,1996, 9 (1):6～12
[4] S Badrinarayanan and N Zabaras. Preform Design in Metal Forming, Processes. NUMIFORM95, Shen and P. Dawson, ed., Ithaca, NY, 1995:533～538
[5] M Hirshrogel, H V Donmelen. Some Applications of Cold and Warm Forging .Journal of Materials Processing Technology, 1992, 35 (6):343～356
[6] 洪深泽.挤压工艺及模具设计.北京:机械工业出版社,1993,1～3,120～121
[7] 高锦张,陈文琳,贾俐俐.塑性成形工艺与模具设计.北京:机械工业出版社,2001,359-361
[8] 吕炎.精密塑性体积成形技术.北京:国防工业出版社,2003,1～3
[9] 杨煜.国内外冷脐压技术发展综述.锻压机械,2001(1):3～5
[10] 孙友松.温/冷挤压复合成形枝术概况.锻压机械, 94(4):7～8
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[12] I Pillinger, P. Hartley, C.E.N.sturgess and CxW.Rowe.An elastic-plastic three-dimensional finite element analysis of upsetting of rectangular blocks and experimental comparison.Int.J.Mach.Tool Eds.Res., 1985,25:229～243
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[14] J.P.Cescutti, N. Sorris, G.Surdon and J.L.Chenot. Thermo-mechanical finite element calculation of three-dimensional hot forging with remeshing. Advanced Technology of Plasticity-Proceedings of the Second ICTP. 1987,2:1051～1058
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[16] V F Paulo Martins and Manuel J.M. barata Marques. Analysis of three-dimensional hexagonal closed-die heading by the finite-element flow formation. J.mater.process.Technol, 1994,43:279～291
[17] A.FPaulo Martins and Manuel J.M. Barata Marques. Analysis of three-dimensional hexagonal closed-die heading by the finite-element flow formulation. J.mater.process.Technol,1993,38:55～56
[18] 胡亚民,温正忠.汽车与冷锻工艺.汽车工艺与材料,96(12):10～11
[19] 郑修麟.材料的力学性能.西北工业大学出版社,1994.6
[20] 俞汉清,陈金德.金属塑性成形原理.机械工业出版社.1999.10
[21] 贾俐俐.挤压成形工艺与模具设计.机械工业出版社.2004.7
[22] 王同海.管材塑性加工技术.节工业出版社.1998.7
[23] 谢水生,王祖唐.金属塑性成形中的摩擦与润滑.冶金工业出版社,1997
[24] 马怀宪,金属塑性加工学——挤压、拉拔与管材冷轧,西安冶金建筑学院,1991.5
[25] 模具使用技术丛书编委会,模具材料与使用寿命,机械工业出版社,2000.4
[26] 谢建新,刘静安.金属挤压理论与技术.冶金工业出版社,2001.5
[27] Juiping Tabg, W.T.Wu. Recent development an applications of finite element method in metal forming, J. Mater. Proc. Tech.,1994(5):117-126
[28] 王仲仁.《塑性加工力学基础》.国防工业出版社,1989
[29] 谢配良等,金属塑性成型过程的计算机模拟,锻压机械,No.4,1997
[30] 董湘怀.金属塑性成形计算机模拟的若干进展.金属成形工艺,No.1, 2000:12～14
[31] Markus Meidert,Taylan.Process Technology.1992,33:75-93
[32] 赵国群等.锻造过程刚—粘塑性有限元模拟系统.机械工程学报,No.6,1992:14～18
[33] 肖景容等.《塑性成形模拟理论》.华中理工大学出版社,1994
[34] Jiao Cao and Mary C. Boyce, Draw bead penetration as a control element of material flow, SAE paper 930517,1993,145～153
[35] 关庭栋等.塑性成形工艺中的金属流动模拟.模具技术,1986(1)
[36] DEFORM用户手册
[37] 茹铮,余望,阮煦寰,孟宪堂.塑性加工摩擦学.科学出版社,1992.8
[38] 王同海.管材塑性加工技术,机械工业出版社,1998.7
[39] 杨伯源,白嘉南,李和平.材料力学冲国科学技术大学,1998
[40] 彭巍,赵玉民,杨金娥.花键管冷挤压成形挤压力的影响因素分析.机械制造,2006.
[2] 易宏展,任运来,冯杨等.花键轴冷挤压成形应用.锻压机械.2002年第5期.2002,37(5)
[3] Zhang zhenchun, LiJun. Experimental Study on Open-die Cold Extrusion Forming Technique for Involute Spline Shafts. Chinese Journal of Mechnical Engineering,1996, 9 (1):6～12
[4] S Badrinarayanan and N Zabaras. Preform Design in Metal Forming, Processes. NUMIFORM95, Shen and P. Dawson, ed., Ithaca, NY, 1995:533～538
[5] M Hirshrogel, H V Donmelen. Some Applications of Cold and Warm Forging .Journal of Materials Processing Technology, 1992, 35 (6):343～356
[6] 洪深泽.挤压工艺及模具设计.北京:机械工业出版社,1993,1～3,120～121
[7] 高锦张,陈文琳,贾俐俐.塑性成形工艺与模具设计.北京:机械工业出版社,2001,359-361
[8] 吕炎.精密塑性体积成形技术.北京:国防工业出版社,2003,1～3
[9] 杨煜.国内外冷脐压技术发展综述.锻压机械,2001(1):3～5
[10] 孙友松.温/冷挤压复合成形枝术概况.锻压机械, 94(4):7～8
[11] J.H.Yoon and D.Y Yang. A three-dimensional rigid-plastic finite element analysis of bevel gear forging by using a remeshing technique. Int.J.Mech.Sci., 1990,32:277
[12] I Pillinger, P. Hartley, C.E.N.sturgess and CxW.Rowe.An elastic-plastic three-dimensional finite element analysis of upsetting of rectangular blocks and experimental comparison.Int.J.Mach.Tool Eds.Res., 1985,25:229～243
[13] G.surdon and J.LChenot. Finite element calculation of three-dimensional hot forging. Num.Mech.Ind.Fonn.Proc., 1986, 2:287～292
[14] J.P.Cescutti, N. Sorris, G.Surdon and J.L.Chenot. Thermo-mechanical finite element calculation of three-dimensional hot forging with remeshing. Advanced Technology of Plasticity-Proceedings of the Second ICTP. 1987,2:1051～1058
[15] I Pllinger, P.Hartley, C.E.Sturgess and CxW.Rowe. Finite element molding of metal flow in three-dimensional forming. Int.J.Num.Meth.Engang.,1988,25:87～98
[16] V F Paulo Martins and Manuel J.M. barata Marques. Analysis of three-dimensional hexagonal closed-die heading by the finite-element flow formation. J.mater.process.Technol, 1994,43:279～291
[17] A.FPaulo Martins and Manuel J.M. Barata Marques. Analysis of three-dimensional hexagonal closed-die heading by the finite-element flow formulation. J.mater.process.Technol,1993,38:55～56
[18] 胡亚民,温正忠.汽车与冷锻工艺.汽车工艺与材料,96(12):10～11
[19] 郑修麟.材料的力学性能.西北工业大学出版社,1994.6
[20] 俞汉清,陈金德.金属塑性成形原理.机械工业出版社.1999.10
[21] 贾俐俐.挤压成形工艺与模具设计.机械工业出版社.2004.7
[22] 王同海.管材塑性加工技术.节工业出版社.1998.7
[23] 谢水生,王祖唐.金属塑性成形中的摩擦与润滑.冶金工业出版社,1997
[24] 马怀宪,金属塑性加工学——挤压、拉拔与管材冷轧,西安冶金建筑学院,1991.5
[25] 模具使用技术丛书编委会,模具材料与使用寿命,机械工业出版社,2000.4
[26] 谢建新,刘静安.金属挤压理论与技术.冶金工业出版社,2001.5
[27] Juiping Tabg, W.T.Wu. Recent development an applications of finite element method in metal forming, J. Mater. Proc. Tech.,1994(5):117-126
[28] 王仲仁.《塑性加工力学基础》.国防工业出版社,1989
[29] 谢配良等,金属塑性成型过程的计算机模拟,锻压机械,No.4,1997
[30] 董湘怀.金属塑性成形计算机模拟的若干进展.金属成形工艺,No.1, 2000:12～14
[31] Markus Meidert,Taylan.Process Technology.1992,33:75-93
[32] 赵国群等.锻造过程刚—粘塑性有限元模拟系统.机械工程学报,No.6,1992:14～18
[33] 肖景容等.《塑性成形模拟理论》.华中理工大学出版社,1994
[34] Jiao Cao and Mary C. Boyce, Draw bead penetration as a control element of material flow, SAE paper 930517,1993,145～153
[35] 关庭栋等.塑性成形工艺中的金属流动模拟.模具技术,1986(1)
[36] DEFORM用户手册
[37] 茹铮,余望,阮煦寰,孟宪堂.塑性加工摩擦学.科学出版社,1992.8
[38] 王同海.管材塑性加工技术,机械工业出版社,1998.7
[39] 杨伯源,白嘉南,李和平.材料力学冲国科学技术大学,1998
[40] 彭巍,赵玉民,杨金娥.花键管冷挤压成形挤压力的影响因素分析.机械制造,2006.