五孔式氧枪喷头底座成形工艺及模具失效研究
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摘要
本文以五孔式氧枪喷头底座挤压成形为研究对象,对该零件的挤压成形过程及其模具的工作状况进行了数值模拟,制定了该挤压件的成形工艺,并对模具进行了失效分析,这对于保证成形件的质量及提高模具使用寿命均具有积极的意义。
首先,根据模拟分析的需要,建立了模具的几何模型以及模拟过程的刚塑性有限元模型,并对模拟中边界情况的定义、材料性能的施加、设备速度的选取和网格的划分等关键问题进行了分析,为模拟和仿真的顺利进行打下了基础。
应用有限元数值模拟方法,对氧枪喷头底座挤压过程进行了三维数值模拟。讨论了坯料大小、变形温度、变形速度和摩擦条件对变形过程中等效应变、等效应力以及挤压力的影响,确定了合理的变形工艺参数。模拟结果显示:在坯料直径为340mm,挤压温度为850℃,挤压速度为5mm/s时,有利于该零件的成形。
在数值模拟结果分析的基础上,制定了氧枪喷头底座挤压成形的工艺方案,并进行了生产试制。实验结果表明,用挤压工艺代替传统工艺生产该零件,有效地提高了材料利用率,降低了生产成本。
经过批量生产后,挤压凸模表面出现裂纹,导致模具失效。本文采用有限元数值模拟软件对凸模挤压过程中的应力场、温度场进行了分析,找出其失效的主要原因,并提出改进方案。
Take the extrusion of the pedestal of 5-hole spray nozzle of oxygen lance as the research object, the numerical simulation of forming process and working condition of die are studied in this paper. The technology of the extruded part has been stipulated, and the failure analysis has been studied. Those are in favor of increasing the part and the service life of die.
Firstly, the geometric model of die and rigid-plastic finite element model of simulation are built according to the demand of simulation analysis. The definition of interface condition between die and workpiece, the adding of material parameters, forming velocity of machine and mesh, is also done. it is the base of the following computer simulation.
Through numerical simulation of finite element method (FEM), the course of extrusion of the spray nozzle of oxygen lance is simulated. The forming of the blank, deformation temperature, deformation rate and friction are discussed which impact equivalent strain, equivalent stress and extrusion force. The analysis showed that it is beneficial to forming when the diameter of blank is 340mm, the extrusion temperature is 850℃, and the extrusion speed is 5mm /s.
Based on the result of the FEM simulation,the extruded forming technology of the spray nozzle of oxygen lance has been stipulated, and the physical experiment is achieved. The result shows that it is feasible to produce the spray nozzle of oxygen lance with extrusion in place of the traditional technology, which improved the utilization of material and reduced the production cost effectively.
Through quantity production, the surface of extruded die of the spray nozzle of oxygen lance appeared crack. It resulted in the ineffectiveness of die. The stress and temperature field of die in the extrusion processes is analyzed using simulation software of finite element method. The main reason of ineffectiveness of die is found, and the improving project is put forward.
首先,根据模拟分析的需要,建立了模具的几何模型以及模拟过程的刚塑性有限元模型,并对模拟中边界情况的定义、材料性能的施加、设备速度的选取和网格的划分等关键问题进行了分析,为模拟和仿真的顺利进行打下了基础。
应用有限元数值模拟方法,对氧枪喷头底座挤压过程进行了三维数值模拟。讨论了坯料大小、变形温度、变形速度和摩擦条件对变形过程中等效应变、等效应力以及挤压力的影响,确定了合理的变形工艺参数。模拟结果显示:在坯料直径为340mm,挤压温度为850℃,挤压速度为5mm/s时,有利于该零件的成形。
在数值模拟结果分析的基础上,制定了氧枪喷头底座挤压成形的工艺方案,并进行了生产试制。实验结果表明,用挤压工艺代替传统工艺生产该零件,有效地提高了材料利用率,降低了生产成本。
经过批量生产后,挤压凸模表面出现裂纹,导致模具失效。本文采用有限元数值模拟软件对凸模挤压过程中的应力场、温度场进行了分析,找出其失效的主要原因,并提出改进方案。
Take the extrusion of the pedestal of 5-hole spray nozzle of oxygen lance as the research object, the numerical simulation of forming process and working condition of die are studied in this paper. The technology of the extruded part has been stipulated, and the failure analysis has been studied. Those are in favor of increasing the part and the service life of die.
Firstly, the geometric model of die and rigid-plastic finite element model of simulation are built according to the demand of simulation analysis. The definition of interface condition between die and workpiece, the adding of material parameters, forming velocity of machine and mesh, is also done. it is the base of the following computer simulation.
Through numerical simulation of finite element method (FEM), the course of extrusion of the spray nozzle of oxygen lance is simulated. The forming of the blank, deformation temperature, deformation rate and friction are discussed which impact equivalent strain, equivalent stress and extrusion force. The analysis showed that it is beneficial to forming when the diameter of blank is 340mm, the extrusion temperature is 850℃, and the extrusion speed is 5mm /s.
Based on the result of the FEM simulation,the extruded forming technology of the spray nozzle of oxygen lance has been stipulated, and the physical experiment is achieved. The result shows that it is feasible to produce the spray nozzle of oxygen lance with extrusion in place of the traditional technology, which improved the utilization of material and reduced the production cost effectively.
Through quantity production, the surface of extruded die of the spray nozzle of oxygen lance appeared crack. It resulted in the ineffectiveness of die. The stress and temperature field of die in the extrusion processes is analyzed using simulation software of finite element method. The main reason of ineffectiveness of die is found, and the improving project is put forward.
引文
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[2] 虞松.金属塑性成形过程三维有限元六面体网格自动生成算法及数值模拟关键技术研究[D].山东大学博士学位论文,2004.9:1-2.
[3] 李炳源.氧枪喷头使用的若干问题[J].冶金丛刊,2000(4):7-8.
[4] 谢建新,刘静安.《金属挤压理论与技术》[M].北京:冶金工业出版社,2001:1
[5] R. Narayanasamy, P. Srinivasan, R. Venkatesan. Computer aided design and manufacture of streamlined extrusion dies[J]. Journal of Materials Processing Technology 138 (2003) 262–264.
[6] 张治民,王强,张保红.复杂盒形零件挤压坯料优化[J].塑性工程学报,2003(3)第 10 卷:30-33.
[7] 于玲.双杯形件挤压工艺研究[D].中北大学硕士学位论文,2006.3:3
[8] 李生智.《金属压力加工概论》[M].北京:冶金工业出版社,1984:153-154.
[9] P. Tiernan , M.T. Hillery , B. Draganescu , M. Gheorghe .Modelling of cold extrusion with experimental verification[J].Journal of Materials Processing Technology 168 (2005) 360–366.
[10] 崔益民.反挤压刚粘塑性有限元模拟研究[D].合肥工业大学学位论文,2000 .2:2.
[11] 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,1991:3-4
[12] 乔中莲.履带板挤压成形工艺研究[D].中北大学硕士学位论文,2006.3:7
[13] 洪深泽.《挤压工艺及模具设计》[M].北京:机械工业出版社,1995:4-5
[14] 刘明俊,孙友松.塑性加工的有限元模拟—工艺过程优化的新工具[J].机电工程技术,2003(5):88-91.
[15] Courant R.Variational. Methods for the Solution of Problems of Equilibrium and Vibrations[J].Bull.Am.Math.Soc,1943,49(2):1-23.
[16] Turner M J, Clough R W, Martin H C, Toop L C.Stiffnessand. Deflection Analysis of Complex Structures[J].J.Aeronant.Sci,1956,23(9):82-86.
[17] 田华,陈军.金属体积成形仿真技术的发展概况[J].模具技术, 2005(1):14-17.
[18] 梁清香,张根全.有限元与 MARC 实现[M].北京:机械工业出版社,2003.1:2.
[19] A.J.Williams,T.N.Croft,M.Cross. Computational modeling of metal extrusion and forging processes[J]. Journal of Materials Processing Technology 125-126(2002)573-582.
[20] 赵健,陈拂晓,上官林健.体积成形的数值模拟[J].模具工业,2001(9):26-29.
[21] B.P.P.A. Gouveia *, J.M.C. Rodrigues, P.A.F. Martins. Finite element modelling of cold forward extrusion using updated Lagrangian and combined Eulerian–Lagrangian formulations[J]. Journal of Materials Processing Technology 80–81(1998) 647–652.
[22] 马琳伟,孙乐民,张巧芳,张永振.数值模拟锻造成形关键技术及应用[J].金属成形工艺,2003(6):17-20
[23] 应富强,张更超,潘孝勇.三维有限元数值模拟技术在金属塑性成形中的应用[J].锻压装备与制造技术,2003(5):10-13.
[24] Dr Brian Miller,Richard Bond. The Practical Use of Simulation in The sheet metal forming Industr[J]. Joint paper presented at the Confederation of British Metalforming Technical Conference2001.
[25] 朱伟,张质良.有限元数值模拟的若干关键技术[J].计算机仿真2004(3):88-91.
[26] J. Zhu, M. Gotoh. An automated process for 3D hexahedral mesh regeneration in metal forming[J]. Computational Mechanics 24 (1999) 373-385.
[27] Hasan Sofuoglu,Hasan Gedikli.Physical and Numerical Analysis of Three Dimensional Extrusion Process[J]. Computational Materials Science, 2004(31):113-124.
[28] 童隆长.塑性加工过程有限元法模拟的现状和困难[J].塑性工程学报:2002(4):1-6.
[29] J. Lof*, Y. Blokhuis. FEM simulations of the extrusion of complex thin-walled aluminium sections[J]. Journal of Materials Processing Technology,2002:244-354.
[30] Young-Tae Kim,Keisuke Ikeda,Tadasu Murakami.Metal flow in porthole die extrusion of aluminiun[J] .Jourmal of Materials Processing Thchnology,2002:107-115.
[31] Tang Juipeng, Wu WT, John Waiters. Recent Development and Application of Finite Element Method in Metal Forming[J]. Journal of Materials Processing Technology, 1994,46:117-126.
[32] Yoon J H, Yang D Y A .Three-dimensional Rigid-plastic Finite Element Analysis of Bevel Gear Forming by Using Remeshing Techniques[J]. International Journal of Mechanical Sciences, 1990, 32(4): 277-291.
[33] Chenot J L, Bay F, Fourment L. Finite Element Simulation of Metal Powder Forming.[J] International Journal for Numerical Methods in Engineering,1990.30 :1649-1674.
[34] Kim H, Sweeney K, Altan T. Application of Computer Aided Simulation to Investigate Metal Flow in Selected Forging Operation[J]. Journal of Materials Processing Technology, 1994, 46: 127-154.
[35] Lange.k,etal. Optimized Cold Forging of Helical Gears by FEM Simulation[J], Processing of International Cold Forming Congress,Solihull,U.K,1995.
[36] 闫洪,胡强,杨国泰等.型材挤压过程金属变形流动的有限元仿真[J].锻压技术,2004(6):46-48.
[37] 周明智,薛克敏.方盒形件精密挤压成形三维弹塑性有限元模拟[J].合肥工业大学学报,2005(8):882-884.
[38] 李炳源.氧气转炉氧枪的设计与使用[J].第十二届全国炼钢学术会议论文,106-110.
[39] 孙正茂,宋战等.转炉氧枪喷头的优化设计与应用[J].鞍钢技术,2000(9):4-9.
[40] 李承祚,张飞虎等.氧气转炉锻压组合式氧枪喷头的研制与应用[J].冶金设备,2002(2):47-50.
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