管材滚珠旋压成形工艺研究
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摘要
随着现代旋压技术的飞速发展,强力旋压已经成为航空、航天、军工等金属精密成形技术领域的先进塑性成形工艺。滚珠旋压作为一种采用滚珠作为变形工具的强力旋压工艺,成为加工制造高强度、高精度薄壁管的新型工艺,在航空航天工业、汽车工业和民用工业中有着举足轻重的地位。
本文基于有限元理论和实际生产过程,采用数值模拟的方法,应用DEFORM-3D分析软件,建立了GH4169筒形件滚珠旋压反旋的三维弹塑性有限元模型,揭示了滚珠旋压反旋时金属的流动规律及工件上应力、应变分布规律。
着重分析了不同的轴向进给比、减薄率和主轴转速等工艺参数对旋压加工成形结果中的等效应力应变及旋压力的影响,并解释说明了旋压过程中出现的一些常见的质量缺陷,如隆起、表面波纹、端口喇叭口等,重点定量分析了隆起缺陷,通过综合考虑合理匹配工艺参数来避免这些缺陷的产生,为旋压工艺参数的选择和优化提供了依据。
根据有限元数值模拟结果,通过实验对模拟结果进行了验证。对于本文所描述的加工工艺条件下,由于采用了合理的旋压工艺参数,避免了旋压中缺陷的产生,成品表面质量良好。数值计算结果与实验结果吻合较好,达到了预期的目的。
同时,本文还对直径为30mm,壁厚仅为0.2mm的不锈钢0Cr18Ni9管材的滚珠旋压工艺进行了研究,着重分析了滚珠直径、减薄率、轴向进给比及主轴转速对成形结果的影响。结果表明壁厚较小,极易产生质量缺陷,如表面起皮、断裂等。减薄率、轴向进给比等工艺参数都应当取较小值。
With the rapid development of modern spinning technology, power spinning has been an advanced plastic forming process in the field of precise metal forming technology of aerospace, aviation and military industry. As a power spinning process which uses balls as deformation tools, ball-spinning has become the new process for manufacturing high-strength, high-precision thin-walled tube. It has a pivotal position in the aerospace industry, automotive and civil industries.
Based on finite element theory and the practical production process in this article, the analysis software DEFORM-3D is applied to build the three dimensional elastic-plastic finite element model of backward ball spinning process for GH4169 tube by using the numerical simulation method. It reveals the metal flowing rule in backward ball spinning process and the rule of stress-strain distribution in the wokpiece.
The influences of the variation of technical parameters such as axial feed ratio, reducing ratio, spindle speed and ball diameter on the equivalent stress, equivalent strain and spinning forces in the tube spinning process have been analyzed in the paper. The emergence of some common quality defects, such as piling, surface ripple, port bellmouth, etc is explained, and focusing on quantitative analysis of piling. It avoids the defects through comprehensive consideration and reasonable matching parameters. It provides the basis for the selection and optimization of spinning process parameter.
According to finite element simulation results, for the processing technique described in this article, the simulation results are verified through experiments. As a result of the reasonable spinning process parameters, it avoids the spinning defects and result in finish products with higher quality. The numerical results agree well with the spinning experimental results, and have achieved the anticipated goal.
At the same time, the ball-spinning process of stainless steel OCrl 8Ni9 tube whose diameter and wall thickness are 30mm and only 0.2mm, respectively has been investigated. It has focused on the analysis of effects of ball diameter, reducing ratio, axial feed ratio and spindle speed on the results of forming. The numerical results show that smaller wall thickness may result in quality defects such as the skin splinter, fracture, etc. The parameters like reducing ratio, axial feed ratio, etc. should be taken as a smaller value.
本文基于有限元理论和实际生产过程,采用数值模拟的方法,应用DEFORM-3D分析软件,建立了GH4169筒形件滚珠旋压反旋的三维弹塑性有限元模型,揭示了滚珠旋压反旋时金属的流动规律及工件上应力、应变分布规律。
着重分析了不同的轴向进给比、减薄率和主轴转速等工艺参数对旋压加工成形结果中的等效应力应变及旋压力的影响,并解释说明了旋压过程中出现的一些常见的质量缺陷,如隆起、表面波纹、端口喇叭口等,重点定量分析了隆起缺陷,通过综合考虑合理匹配工艺参数来避免这些缺陷的产生,为旋压工艺参数的选择和优化提供了依据。
根据有限元数值模拟结果,通过实验对模拟结果进行了验证。对于本文所描述的加工工艺条件下,由于采用了合理的旋压工艺参数,避免了旋压中缺陷的产生,成品表面质量良好。数值计算结果与实验结果吻合较好,达到了预期的目的。
同时,本文还对直径为30mm,壁厚仅为0.2mm的不锈钢0Cr18Ni9管材的滚珠旋压工艺进行了研究,着重分析了滚珠直径、减薄率、轴向进给比及主轴转速对成形结果的影响。结果表明壁厚较小,极易产生质量缺陷,如表面起皮、断裂等。减薄率、轴向进给比等工艺参数都应当取较小值。
With the rapid development of modern spinning technology, power spinning has been an advanced plastic forming process in the field of precise metal forming technology of aerospace, aviation and military industry. As a power spinning process which uses balls as deformation tools, ball-spinning has become the new process for manufacturing high-strength, high-precision thin-walled tube. It has a pivotal position in the aerospace industry, automotive and civil industries.
Based on finite element theory and the practical production process in this article, the analysis software DEFORM-3D is applied to build the three dimensional elastic-plastic finite element model of backward ball spinning process for GH4169 tube by using the numerical simulation method. It reveals the metal flowing rule in backward ball spinning process and the rule of stress-strain distribution in the wokpiece.
The influences of the variation of technical parameters such as axial feed ratio, reducing ratio, spindle speed and ball diameter on the equivalent stress, equivalent strain and spinning forces in the tube spinning process have been analyzed in the paper. The emergence of some common quality defects, such as piling, surface ripple, port bellmouth, etc is explained, and focusing on quantitative analysis of piling. It avoids the defects through comprehensive consideration and reasonable matching parameters. It provides the basis for the selection and optimization of spinning process parameter.
According to finite element simulation results, for the processing technique described in this article, the simulation results are verified through experiments. As a result of the reasonable spinning process parameters, it avoids the spinning defects and result in finish products with higher quality. The numerical results agree well with the spinning experimental results, and have achieved the anticipated goal.
At the same time, the ball-spinning process of stainless steel OCrl 8Ni9 tube whose diameter and wall thickness are 30mm and only 0.2mm, respectively has been investigated. It has focused on the analysis of effects of ball diameter, reducing ratio, axial feed ratio and spindle speed on the results of forming. The numerical results show that smaller wall thickness may result in quality defects such as the skin splinter, fracture, etc. The parameters like reducing ratio, axial feed ratio, etc. should be taken as a smaller value.
引文
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[3]李德群.塑性加工技术发展状况及趋势.航空制造技术,2000,(3)：27-28
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[5]刘建华,杨合,李玉强.旋压技术基本原理的研究现状与发展趋势.重型机械,2002,(3)：1-4,12
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[8]江树勇,薛克敏,孙权颖.薄壁筒形件滚珠旋压成形工装设计及实验研究[J].林业机械与木工设备,2005,2：28-30
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[10]王仲仁,海锦涛.世纪之交的塑性加工技术.见：海锦涛,张立斌,陆辛.先进制造技术.北京,1996.北京：机械工业出版社,1996：48-50
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[12]Huang Z J, Chen D H, and Lei Y Z. Developing Tendency of Research on Technology of Plasticity from the Viewpoint of NSFC. in:Wang Z R and He Y X eds. Advanced Technology of Plasticity 1993.Beijing:International Academic Publishers,1993:315-319
[13]郑莹,吴勇国,李尚健等.板料成形数值模拟进展.塑性工程学报.1996,3(4)：34-43
[14]张士宏,王仲仁.有限元法在板料成形分析中的应用进展.金属成形工艺.1992,10(4)：145-149
[15]叶又,彭颖红,阮雪榆.三维板料成形过程的数值模拟.上海交通大学学报.1998,32(5)：6-9
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[17]郑莹,吴勇国.板材成形数值模拟进展.塑性工程学报.1996.(4)：6-14
[18]Yang Qingchun, Qu shengnian, Zhou Qi, Min Naiyan. FE Simulation Method for Forging system. Journal of Material Processing Technology.1997. (3):678-683
[19]赵云豪,李彦利.旋压技术与应用.机械工业出版社.2007：3-5,74,163
[20]陈适先.我国旋压事业的发展与展望[J].锻压与冲压.2005,(10)：20-25
[21]陈适先等.锻压手册[M].北京：机械工业出版社.2002：505-565
[22]叶山益次郎汇[日].旋压加工原理及工艺讲义.有色金属研究总院译.1983.100-150
[23]C.L. Packham. Metal Spinning and Shear and Flow Forming. Sheet Metal Industries.1977,17(4):382-389
[24]K.X. Chen. Metal Spinning Technique in China and Through of the World in 1980's Proceeding of 3rd.ICRF.Beijing.1989,(10):75-78
[25]Eamonn Quigley, John Monaghan. Metal Forming:an Analysis of Spinning Process. Journal of Materials Technology.2000,103(3):114-119
[26]旋压标准.JB/T7523—1094
[27]叶山益次郎.回转塑性加工学.近代编辑社,1978
[28]王成和,刘克璋等.旋压技术.北京：机械工业出版社.1986：1-13,48-49,65-66,206,637-689
[29]周照耀,王真等.筒形件强力按压的刚塑性有限元分析.塑性工程学报.1994,(3)：37
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