基于有限元模拟的衔铁零件挤压模型腔优化设计
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摘要
冷挤压技术是一种高精、高效、优质低耗的先进生产工艺技术,已成为当今塑性加工领域重点研究和发展的方向之一。本文研究的Z型衔铁零件是某电磁继电器的关键部件,属于异形非对称件,其几何形状复杂,精度要求高,加工难度大,采用传统加工工艺方法进行生产,难以满足企业日益增长的需求,已经成为制约企业发展的瓶颈。文章针对衔铁零件的工艺特点,创造性的提出了冷挤压加工方法制造衔铁零件的方案。
文章采用理论分析、有限元数值模拟和实验研究相结合的方法,对Z型衔铁冷挤压成形工艺、模具设计及其关键技术进行了研究。在对衔铁零件进行工艺分析的基础上,对衔铁零件挤压模具进行了结构设计。文章从衔铁零件冷挤压成形的关键部件-凹模型腔入手,采用正交设计方法,结合有限元分析软件DEFORM-3D,对影响挤压力的凹模型腔结构参数进行优化设计,得到最优化的凹模结构参数。在此基础上,文章对优化后的结构进行模拟,得到变形过程的行程―载荷曲线、应力、应变场等信息,并分析模具的应力情况,将凹模结构改为纵向剖分式以改善应力集中现象。
为验证凹模优化设计结果,本文在挤压机上进行了多次挤压工艺试验,得到了有价值的实验结果。试验结果表明,Z型衔铁正向冷挤压工艺方案和模具结构基本可行,同时验证了型腔优化结果对降低挤压力的有效性。
The goal of the investigation is to theoretically and experimentally demonstrate the key points of using extrusion-die to manufacture armature part, which is a kind of asymmetry iron‘Z’shape work piece that is often used in relay assembly. The work piece is a complex one with high degree of accuracy. The common way to manufacture it contains several machining procedures resulting high costs and low efficiency which becomes the bottleneck of the company to meet the need of market. To overcome these difficulties, this paper creatively adopts cold extrusion method to make it.
Basic plastic deforming theory and FEM software and experiments are used to study the cold forming of the part in this paper. Over the analysis of the processing property, a structure of the extrusion die is designed for the research. In order to gain the lowest load, the orthogonal design combined with DEFORM-3D is adopted to optimize parameters of the cavity which is the key part of the extrusion die. The inner stress field, strain field, metal flowing law and forging travel-load curve during the forming procedure of the optimized structure are figured out after the simulation, and structure of the die is changed as longitudinal divided cavity to avoid stress concentration.
Extrusion experiments were done to verify the optimization, and several satisfied net-shape work pieces with smooth surface were gained. The accomplishment of the experiments demonstrates that extrusion die can be successfully used to manufacture asymmetry parts, and the optimization is effective to reduce the extrusion force. This innovative research also has practical reference values for die design.
文章采用理论分析、有限元数值模拟和实验研究相结合的方法,对Z型衔铁冷挤压成形工艺、模具设计及其关键技术进行了研究。在对衔铁零件进行工艺分析的基础上,对衔铁零件挤压模具进行了结构设计。文章从衔铁零件冷挤压成形的关键部件-凹模型腔入手,采用正交设计方法,结合有限元分析软件DEFORM-3D,对影响挤压力的凹模型腔结构参数进行优化设计,得到最优化的凹模结构参数。在此基础上,文章对优化后的结构进行模拟,得到变形过程的行程―载荷曲线、应力、应变场等信息,并分析模具的应力情况,将凹模结构改为纵向剖分式以改善应力集中现象。
为验证凹模优化设计结果,本文在挤压机上进行了多次挤压工艺试验,得到了有价值的实验结果。试验结果表明,Z型衔铁正向冷挤压工艺方案和模具结构基本可行,同时验证了型腔优化结果对降低挤压力的有效性。
The goal of the investigation is to theoretically and experimentally demonstrate the key points of using extrusion-die to manufacture armature part, which is a kind of asymmetry iron‘Z’shape work piece that is often used in relay assembly. The work piece is a complex one with high degree of accuracy. The common way to manufacture it contains several machining procedures resulting high costs and low efficiency which becomes the bottleneck of the company to meet the need of market. To overcome these difficulties, this paper creatively adopts cold extrusion method to make it.
Basic plastic deforming theory and FEM software and experiments are used to study the cold forming of the part in this paper. Over the analysis of the processing property, a structure of the extrusion die is designed for the research. In order to gain the lowest load, the orthogonal design combined with DEFORM-3D is adopted to optimize parameters of the cavity which is the key part of the extrusion die. The inner stress field, strain field, metal flowing law and forging travel-load curve during the forming procedure of the optimized structure are figured out after the simulation, and structure of the die is changed as longitudinal divided cavity to avoid stress concentration.
Extrusion experiments were done to verify the optimization, and several satisfied net-shape work pieces with smooth surface were gained. The accomplishment of the experiments demonstrates that extrusion die can be successfully used to manufacture asymmetry parts, and the optimization is effective to reduce the extrusion force. This innovative research also has practical reference values for die design.
引文
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[3]周琨,陈国学.伞齿轮精密成形模具变形的数值模拟分析.塑性工程学报,2002, 9(1):74～78
[4]欧阳瑞丽,农组伟,蒋美莲.渐开线花键冷挤压成形工艺.模具工业,2003, 4(266): 42～44
[5]刘全坤,李冬生.基于流线型凹模型腔的直齿圆柱齿轮冷挤压数值模拟分析.工程设计学报,2005,12(1):15～19
[6]张清萍,赵国群,栾贻国.齿轮冷精锻工艺预锻模具齿形优化设计.机械科学与技术,2004,23(12):1487～1490
[7]金俊松,夏巨谌,王新云.非对称件摆辗组合凹模优化设计.模具工业,2005,1 (287): 30～34
[8]任发才,赵国群,王广春.活塞头挤压工艺模具设计与数值模拟优化.锻压技术, 2006,4:49～53
[9]陈莉,宋宝韫,运新兵.铜扁线挤压模腔内材料成形的数值模拟.塑性工程学报,2003,10(6):66～69
[10]郑荣,包忠诩,周天瑞等.三维铝型材挤压模多参数优化.模具设计与制造, 2004, 22 (1):69～72
[11]齐红元,杜风山,刘才.金属异型材挤压模参数的优化.模具工业,2000,2(228): 33～36
[12]闫洪,夏巨谌,包忠诩.型材挤压模工作带长度设计计算的数学建模.塑性工程学报,2002,9(1):70～73
[13]姜文举,王丽巍. S板型材挤压模具的优化设计.模具制造,2006,10:67～69
[14]孙朝华.铝型材挤压过程数值模拟及模具优化设计: [博士学位论文].太原:太原理工大学,2004.
[15]许树勤,张善元.分流组合模挤压的有限元模拟与模具设计评价.模具工业,2005, 6(292):40～44
[16]王英,段道华,夏巨谌等.正向热挤压凹模优化设计方法的研究.中国机械工程,1997,8(4): 49～52
[17]刘金德,邢建东.材料成形技术基础.北京:机械工业出版社, 2000.
[18]夏巨谌.精密塑性成形工艺.北京:机械工业出版社,1999.
[19]胡忠.材料加工过程计算机模拟的现状与未来.塑性工程学, 1998, 5(2): 1～8
[20]周朝辉,曹海桥,吉卫等.应用有限元分析软件进行金属塑性成形研究.制造技术与实践, 2004,5:34～36
[21] Beong Du Ko, Dong Joon Kim, Soo Hyung Lee et al. The influence of die geometry on the radial extrusion process. Journal of Materials Processing Technology, 2001, 11(3):103～114
[22] Stephane Despreaux, Patrick Witomski. Optimal shape in crystal process. Journal of Crystal Growth, 2000, 20(9):983～993
[23] Daw-Kwei, Tsung-chia chen,You-Min Huang. Influence of punch shape on the collar-drawing process of sheet steel. Journal of Materials Processing Technology, 1999,8(8):134～136
[24] Hyunbo Shim. Optimal perform design for the free forging of 3D shapes. Journal of Materials Processing Technology, 2003, 13(4): 99～107
[25] Glavardanov Valentin B., Atanackovic Teodor M.. Optimal shape of a twisted and compressed rod. European Journal of Mechanics-A/Solids, 2001, 20(5): 795～809
[26] Cherkaev A.V., GrabovsY., Movehan A. B.,Serkov S. K. The cavity of optimal shape under the shear stresses. International Journal of Solids and Structures, 1998, 35(33):4391～4410
[27]佘斌.薄壁方锥形件冷挤压变形过程的分析及数值模拟: [博士学位论文].北京:北京科技大学,2005.
[28]马新武,何东,赵国群等.多型腔锻造过程预锻模形状优化设计.中国机械工程, 2000,18 (8):865～867
[29] D. Hortig, D. Schmoeckel. Analysis of local loads on the draw die profile with regard to wear using the FEM and experimental investigations. Journal of Materials Processing Technology, 2001, 11(5):153～158
[30] S. Carneiro, J. M. Nobrega, F. T. Pinho and Oliveira. Computer aided theological design of extrusion dies for profile. Journal of Materials Processing Technology,2001,11(4): 75～86
[31]高汉华.有限元分析在组合凹模设计中的应用.轻工机械, 2006,24(2):93～95
[32]刘英卫.三维形状优化设计.计算机结构力学及其应用, 1995,2(1):7～10
[33]罗仁平.锻造过程预成形计算机辅助优化设计研究:[博士学位论文].上海:上海交通大学,1999.
[34] Zhao Guoqun. Computer aided perform in forging using the inverse die contact tracking method. Int. J. Mach. Tools & Manufacture, 1996,36(7): 755～769
[35] Park J. J. al.. A new approach to perform design in forging forming with the finite element Method. Int. J. Mach. Des. Res., 1983, 23(1): 1～79
[36] Braibant V., Fleury C. Shape optimal design using B-spline. Computer Meth. Appl. Mech.Eng., 1984,44:247～267
[37]肖向宏.形状优化中关键技术的研究与应用:[博士学位论文].武汉:华中理工大学,1993.
[38]王学林.基于物理的参数化方法及其形状优化的集成:[博士学位论文].武汉:华中理工大学,1998.
[39]赵新海,赵国群,王广春等.单工序少无毛边锻造过程预制坯形状优化设计.模具技术, 2000,(4):8～11
[40]李燕.扁挤压筒受力与变形分析及结构优化设计研究:[博士学位论文].合肥:合肥工业大学,2005.
[41] Zienkiewiez O.C, Cambell J.C. Shape optimization and Sequential linear programming in optimum structural design. Tohn Wiley, New York,1973
[42] Iman,M.H.. Three-dimensional shape optimization. Mech.Eng,1982,18(1): 661～673
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