连续挤压机挤压轮使用寿命研究
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摘要
挤压轮是连续挤压成型(CONFORM, Continuous Extrusion Forming)机的关键部件,由于其在工作中承受压力、热应力及摩擦力的综合作用,所以对模具材质有较高要求,要求很高的强韧性配合,一般选择H13热作模具钢作为CONFORM连续挤压机挤压轮用钢,但有一部分挤压轮的寿命较短,发生非正常损坏失效,严重的降低了生产效率,增加了生产成本。了解其早期失效的原因对进一步改进挤压轮的制造工艺、提高寿命有很大的指导作用。
本文围绕挤压轮寿命这一问题,主要从失效分析、受力及材料上来展开研究工作。首先,分析非正常损坏失效原因。在连续挤压生产现场取回新鲜断口试样,主要采用光学金相显微镜和扫描电子显微镜等仪器,对挤压轮的断口进行了宏观分析、化学成分分析、硬度分析、金相分析和开裂面电子形貌分析研究。试验研究结果表明,挤压轮槽表面留有肉眼可见加工划痕,在划痕处先形成热疲劳裂纹,萌生了裂纹源,在高应力集中下最终使挤压轮产生疲劳断裂。
然后,对应力集中产生断裂的过程进行研究。结合挤压轮实际生产中的受力情况,建立ANSYS有限元模型,分析挤压轮轮槽、键槽部位在实际生产过程中应力及变形情况,对结果进行总结得出挤压轮工作区与挡料块接触部位的应力、变形较大,在这样的应力下轮槽发生形变,工作区与非工作区轮槽处于来回弯曲状态下,与实际发生断裂的部位相吻合。
最后,根据裂纹萌生扩展与组织性能的关系,对挤压轮材料组织性能进行研究。主要与超细化材料的组织性能做对比分析,比较两者组织性能上的差异,分析主要原因,对挤压轮材料进行改进。降低回火温度能显著提高挤压轮的强度,韧性略有下降。
Extrusion wheel is a key die in the continuous extrusion forming Machine,because of its work under Comprehensive role of pressure, thermal stress and friction, so has high requirements to the die materials, demanding moreStrength and toughness, generally, we selected hot work die steel of H13 as the continuous extrusion wheel’s material, but some of them have the low life,damaged in adnormally failure, a serious result in reducting production efficiency and increasing production cost.Analysys the reasons for its early failure hasa great guide for further improve the extrusion wheel manufacturing process.
This text around extrusion wheel life this problem,primarily from failure analysis materials and force to study.
First,failure analysis to non-normal damage fracture. Collecting fresh fracture sample from continuous extrusion production. Optical microscope and scanning electron microscope and other instruments were carried out Macro-examination, chemical composition analysis, hardness testing, microstructure examination and fracture analysis on the cracked die. Experimental results show that the extrusion wheel groove have visible machining scratches in the surface, and first formed thermal fatigue crack in the scratch, source of crack initiation, the extrusion wheel happened fatigue fracture under the high stress concentration.
Then, study on the process of fracture under stress.Combination of extrusion wheel force in the actual production situation,estabblish ANSYS finite element model to analyze the stress and deformation in the wheel groove and keyway position which in the normal work force state,come to the work area at the extrusion wheel gauge quick access to parts of the stress has the largest stress, round groove has deformed on this stress, a alternate loading work on non-working and working area which consistent with the actual site of fracture.
Finally, acorrding to the relationship between crack iniation expansion and microstructure, to research on extrusion wheel’s miscrostructure and properties. Mainly to do comparative analysis with ultrafine material’s microstructure and properties, comparing the difference of miscrostructure and properties between the them, and analyze the main reason to improve the extrusion wheel’s material.Lower tempering temperature can significantly improve the extrusion wheel strength,toughness decreased slightly.
本文围绕挤压轮寿命这一问题,主要从失效分析、受力及材料上来展开研究工作。首先,分析非正常损坏失效原因。在连续挤压生产现场取回新鲜断口试样,主要采用光学金相显微镜和扫描电子显微镜等仪器,对挤压轮的断口进行了宏观分析、化学成分分析、硬度分析、金相分析和开裂面电子形貌分析研究。试验研究结果表明,挤压轮槽表面留有肉眼可见加工划痕,在划痕处先形成热疲劳裂纹,萌生了裂纹源,在高应力集中下最终使挤压轮产生疲劳断裂。
然后,对应力集中产生断裂的过程进行研究。结合挤压轮实际生产中的受力情况,建立ANSYS有限元模型,分析挤压轮轮槽、键槽部位在实际生产过程中应力及变形情况,对结果进行总结得出挤压轮工作区与挡料块接触部位的应力、变形较大,在这样的应力下轮槽发生形变,工作区与非工作区轮槽处于来回弯曲状态下,与实际发生断裂的部位相吻合。
最后,根据裂纹萌生扩展与组织性能的关系,对挤压轮材料组织性能进行研究。主要与超细化材料的组织性能做对比分析,比较两者组织性能上的差异,分析主要原因,对挤压轮材料进行改进。降低回火温度能显著提高挤压轮的强度,韧性略有下降。
Extrusion wheel is a key die in the continuous extrusion forming Machine,because of its work under Comprehensive role of pressure, thermal stress and friction, so has high requirements to the die materials, demanding moreStrength and toughness, generally, we selected hot work die steel of H13 as the continuous extrusion wheel’s material, but some of them have the low life,damaged in adnormally failure, a serious result in reducting production efficiency and increasing production cost.Analysys the reasons for its early failure hasa great guide for further improve the extrusion wheel manufacturing process.
This text around extrusion wheel life this problem,primarily from failure analysis materials and force to study.
First,failure analysis to non-normal damage fracture. Collecting fresh fracture sample from continuous extrusion production. Optical microscope and scanning electron microscope and other instruments were carried out Macro-examination, chemical composition analysis, hardness testing, microstructure examination and fracture analysis on the cracked die. Experimental results show that the extrusion wheel groove have visible machining scratches in the surface, and first formed thermal fatigue crack in the scratch, source of crack initiation, the extrusion wheel happened fatigue fracture under the high stress concentration.
Then, study on the process of fracture under stress.Combination of extrusion wheel force in the actual production situation,estabblish ANSYS finite element model to analyze the stress and deformation in the wheel groove and keyway position which in the normal work force state,come to the work area at the extrusion wheel gauge quick access to parts of the stress has the largest stress, round groove has deformed on this stress, a alternate loading work on non-working and working area which consistent with the actual site of fracture.
Finally, acorrding to the relationship between crack iniation expansion and microstructure, to research on extrusion wheel’s miscrostructure and properties. Mainly to do comparative analysis with ultrafine material’s microstructure and properties, comparing the difference of miscrostructure and properties between the them, and analyze the main reason to improve the extrusion wheel’s material.Lower tempering temperature can significantly improve the extrusion wheel strength,toughness decreased slightly.
引文
[1]程培源等,模具寿命与材料.冶金工业出版社,1999(1):3-14
[2]模具实用技术丛书编委会.模具材料与使用寿命[M]北京:机械工业出版社,2000.
[3]曾珊琪,丁毅.模具寿命与失效[M].北京:化学工业出版社,2005.
[4]朱心昆,赵应富.预先热处理对H13钢疲劳寿命的影响.金属热处理,1996(9):19-21
[5]俞德刚,谈育煦.钢的组织强度学-组织与强韧性.上海科技出版社,1983
[6]司鹏程,叶伟江.热作模具材料的进展.金属热处理,1993(1):10-13
[7]浙江大学等,钢铁材料及其热处理工艺.上海科学技术出版社,1987.
[8]约.盖勒,工具钢,国防工业出版社.1983.
[9]阮明.H13横向模块—提高铝挤压模寿命的重要途径.大连钢厂内部资料
[10]刘以宽,李润宝.热作模具的选材及H13钢的应用.上海金属, 1986,8(6):13-20
[11]张树松,仝爱莲.钢的强韧化机理与技术途径.兵器工业出版社.1995
[12]尚纪美.金属的韧性与韧化.上海科学技术出版社,1982.
[13] Green D.Uk patent 13708914.Filed March 1971
[14]王荣.汽车螺栓断裂失效分析[J],理化检验一物理分册,上海,2005,41(9),471.
[15]王春亮,孙浩,李晋,等.电机连接轴失效分析[J].理化检验一物理分册,2005,41(1l),554.
[16]刘正义,吴连生,等.机械装备失效分析图谱[M].广州:广东科技出版社,1990.
[17]航空工业部科学技术委员会.应力集中系数手册〔M〕.北京:高等教育出版社,1990.
[18]杨志坤,王邦龙.H13钢连杆锻模的寿命研究[J].热加工工艺,2004,(3):35-36.
[19]王丽娟,张国福,宋天民,等.泵轴失效分析[J].金属热处理,2006,31(l):87一91.
[20]李健彰,陈泽.影响铝挤压模具寿命的因素探讨〔J〕.冶金丛刊,23,1475.
[21]朱宗元,崔良.我国模具钢及其热处理1艺和标准的发展现状[J],理化检验一物理手册,上海,2007屏3.
[22]张朝晖.ANSYS11.0结构分析工程应用实例解析[M].北京:机械工业出版社,2008
[23]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西安:西北工业大学出版社,1999
[24]陈精一,蔡国忠.电脑辅助工程分析:ANSYS使用指南[M].中国铁道出版社,2001
[25]博嘉科技.有限元分析软件:ANSYS融汇与贯通[M].水利水电出版社,2002
[26]白葳,喻海良.通用有限元分析ANSYS 8.0基础教程[M].清华大学出版社,2005
[27]博弈创作室.ANSYS7.0基础教程与实例详解[M].中国水利水电出版社,2004
[28] ANSYS Inc.Operations Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[29]李明典,宋宝韫等.连续挤压轮槽塑变区应力分析及几何参数的确定[J].塑性工程学报,1999,6(3):25-30.
[30] ANSYS Inc.Element Reference Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[31] ANSYS Inc.Structural Analysis Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[32]沈养中,石静.结构力学[M] .北京:科学出版社,2001
[33]刘明辉.大客车骨架结构静动态特性分析[D].大连:大连理工大学,2005
[34]缪炳荣,肖守纳.ANSYS在机车车体结构设计中的应用[J].内燃机车,2003,(6):4-6.
[35]钟松.范植金.陈跃南.电渣冶炼工艺对H13钢质量的影响.钢铁,1999,34(Suppl):1096-1098
[36]胡志忠.钢及其热处理曲线手册.国防工业工业出版社,1986
[37]冯安华.H13钢常规处理与细化处理的组织与性能.华东冶金学院学报,1989,6(1):34
[38]张益众,李在先等.H13钢热处理工艺对性能的影响.(东北大学学报自然科学版),1996,17(2):187
[39]陈青,张殿香等.热作模具钢4Cr5MoSiV1(H13)钢的组织和性能研究.大连理工大学研究资料.
[40] Louis Malpocker .Die Casting Tool Steels and Their heat Treatment.DIE CASTING ENGINEER,1985(July/August):16-26
[41]李仁顺.金属的延迟断裂及防护.哈尔滨工业大学出版社.1992
[2]模具实用技术丛书编委会.模具材料与使用寿命[M]北京:机械工业出版社,2000.
[3]曾珊琪,丁毅.模具寿命与失效[M].北京:化学工业出版社,2005.
[4]朱心昆,赵应富.预先热处理对H13钢疲劳寿命的影响.金属热处理,1996(9):19-21
[5]俞德刚,谈育煦.钢的组织强度学-组织与强韧性.上海科技出版社,1983
[6]司鹏程,叶伟江.热作模具材料的进展.金属热处理,1993(1):10-13
[7]浙江大学等,钢铁材料及其热处理工艺.上海科学技术出版社,1987.
[8]约.盖勒,工具钢,国防工业出版社.1983.
[9]阮明.H13横向模块—提高铝挤压模寿命的重要途径.大连钢厂内部资料
[10]刘以宽,李润宝.热作模具的选材及H13钢的应用.上海金属, 1986,8(6):13-20
[11]张树松,仝爱莲.钢的强韧化机理与技术途径.兵器工业出版社.1995
[12]尚纪美.金属的韧性与韧化.上海科学技术出版社,1982.
[13] Green D.Uk patent 13708914.Filed March 1971
[14]王荣.汽车螺栓断裂失效分析[J],理化检验一物理分册,上海,2005,41(9),471.
[15]王春亮,孙浩,李晋,等.电机连接轴失效分析[J].理化检验一物理分册,2005,41(1l),554.
[16]刘正义,吴连生,等.机械装备失效分析图谱[M].广州:广东科技出版社,1990.
[17]航空工业部科学技术委员会.应力集中系数手册〔M〕.北京:高等教育出版社,1990.
[18]杨志坤,王邦龙.H13钢连杆锻模的寿命研究[J].热加工工艺,2004,(3):35-36.
[19]王丽娟,张国福,宋天民,等.泵轴失效分析[J].金属热处理,2006,31(l):87一91.
[20]李健彰,陈泽.影响铝挤压模具寿命的因素探讨〔J〕.冶金丛刊,23,1475.
[21]朱宗元,崔良.我国模具钢及其热处理1艺和标准的发展现状[J],理化检验一物理手册,上海,2007屏3.
[22]张朝晖.ANSYS11.0结构分析工程应用实例解析[M].北京:机械工业出版社,2008
[23]王国强.实用工程数值模拟技术及其在ANSYS上的实践[M].西安:西北工业大学出版社,1999
[24]陈精一,蔡国忠.电脑辅助工程分析:ANSYS使用指南[M].中国铁道出版社,2001
[25]博嘉科技.有限元分析软件:ANSYS融汇与贯通[M].水利水电出版社,2002
[26]白葳,喻海良.通用有限元分析ANSYS 8.0基础教程[M].清华大学出版社,2005
[27]博弈创作室.ANSYS7.0基础教程与实例详解[M].中国水利水电出版社,2004
[28] ANSYS Inc.Operations Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[29]李明典,宋宝韫等.连续挤压轮槽塑变区应力分析及几何参数的确定[J].塑性工程学报,1999,6(3):25-30.
[30] ANSYS Inc.Element Reference Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[31] ANSYS Inc.Structural Analysis Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[32]沈养中,石静.结构力学[M] .北京:科学出版社,2001
[33]刘明辉.大客车骨架结构静动态特性分析[D].大连:大连理工大学,2005
[34]缪炳荣,肖守纳.ANSYS在机车车体结构设计中的应用[J].内燃机车,2003,(6):4-6.
[35]钟松.范植金.陈跃南.电渣冶炼工艺对H13钢质量的影响.钢铁,1999,34(Suppl):1096-1098
[36]胡志忠.钢及其热处理曲线手册.国防工业工业出版社,1986
[37]冯安华.H13钢常规处理与细化处理的组织与性能.华东冶金学院学报,1989,6(1):34
[38]张益众,李在先等.H13钢热处理工艺对性能的影响.(东北大学学报自然科学版),1996,17(2):187
[39]陈青,张殿香等.热作模具钢4Cr5MoSiV1(H13)钢的组织和性能研究.大连理工大学研究资料.
[40] Louis Malpocker .Die Casting Tool Steels and Their heat Treatment.DIE CASTING ENGINEER,1985(July/August):16-26
[41]李仁顺.金属的延迟断裂及防护.哈尔滨工业大学出版社.1992