热旋压轮缘对称增厚成形数值模拟及实验研究
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摘要
在加热条件下通过旋压成形的方法对圆形板料轮缘进行对称增厚,最终得到一种辐板较薄而轮缘较厚的盘形类零件,并借助ABAQUS仿真软件建立有限元模型来研究对称增厚成形过程。结果表明,在热旋压对称增厚成形过程中,径向旋压分力逐渐增大,而轴向和切向方向的旋压分力相对较小。对工艺参数的研究表明,摩擦系数μ和型槽倾角α取相对较小值时有利于成形,而进给比f取相对较大值时会更合适。随着坯料长厚比γ和成形增厚比η的不断增大,旋压对称增厚成形呈现出不同的变形特征。当γ过大时,成形易出现屈曲失稳;当η过大时,成形易出现鼓起失稳。最后,选取了一组合适的工艺参数进行增厚实验,实验得到的成形件与模拟结果吻合,验证了工艺的可靠性。
The circular plate rim was symmetrically thickened by the method of spinning under heating conditions,and a disk-shaped part with a thin web and a thick rim was obtained finally. Then,the finite element model was established by ABAQUS software,and the symmetric thickening forming process was studied. The results show that during the hot spinning symmetric thickening forming process,the radial spinning force is gradually increased,while the axial and tangential spinning force are relatively small. The studies on the process parameters indicate that the small friction coefficient μ and groove incline angle α are favorable for forming,and large feed ratio f is more suitable. With the increasing of length-to-thickness ratio γ and forming thickening ratio η,the symmetric thickening forming process exhibits different deformation characteristics. When γ is too large,the forming is prone to buckling instability,however,when η is too large,the forming is prone to bulge instability. Finally,the thickening experiment is conducted by choosing a set of suitable process parameters,and the experiment result is in good agreement with the simulation result to verify the process reliability.
The circular plate rim was symmetrically thickened by the method of spinning under heating conditions,and a disk-shaped part with a thin web and a thick rim was obtained finally. Then,the finite element model was established by ABAQUS software,and the symmetric thickening forming process was studied. The results show that during the hot spinning symmetric thickening forming process,the radial spinning force is gradually increased,while the axial and tangential spinning force are relatively small. The studies on the process parameters indicate that the small friction coefficient μ and groove incline angle α are favorable for forming,and large feed ratio f is more suitable. With the increasing of length-to-thickness ratio γ and forming thickening ratio η,the symmetric thickening forming process exhibits different deformation characteristics. When γ is too large,the forming is prone to buckling instability,however,when η is too large,the forming is prone to bulge instability. Finally,the thickening experiment is conducted by choosing a set of suitable process parameters,and the experiment result is in good agreement with the simulation result to verify the process reliability.
引文
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[6]Davidson M J,Balasubramanian K,Tagore G R N.Experimental investigation on flow-forming of AA6061 alloy-A Taguchi approach[J].Journal of Materials Processing Technology,2008,200(1-3):283-287.
[7]Xia Q X,Xie S W,Huo Y L,et al.Numerical simulation and experimental research on the multi-pass neck-spinning of non-axisymmetric offset tube[J].Journal of Materials Processing Technology,2008,206(1-3):500-508.
[8]Hauk S,Vazquez V H,Altan T.Finite element simulation of the flow-splitting-process[J].Journal of Materials Processing Technology,2000,98(1):70-80.
[9]夏琴香,王甲子,王映品,等.多楔带轮旋压增厚成形阶段金属流动规律分析[J].锻压技术,2009,34(6):101-106.Xia Q X,Wang J Z,Wang Y P,et al.Analysis on metal flow and deformation mechanism during thickening process of poly-wedge pulley spinning[J].Forging&Stamping Technology,2009,34(6):101-106.
[10]Jin J S,Deng L,Wang X Y,et al.A new rotary forming process for rim thickening of a disc-like sheet metal part[J].Journal of Materials Processing Technology,2012,212(11):2247-2254.
[11]Jin J S,Wang X Y,Li L.A sheet blank rotary forging process for disk-like parts with thickened rims[J].Journal of Mechanical Science and Technology,2016,30(6):2723-2729.
[2]王成和,刘克璋.旋压技术[M].北京:机械工业出版社,1986.Wang C H,Liu K Z.Spinning Technology[M].Beijing:China Machine Press,1986.
[3]Awiszus B.Metal spinning of non-circular hollow parts[A].The8th International Conference on Technology of Plasticity[C].Verona,Italy,2005.
[4]Hrtel S,Laue R.An optimization approach in non-circular spinning[J].Journal of Materials Processing Technology,2016,229:417-430.
[5]Jia Z,Han Z R,Xu Q,et al.Effects of processing parameters on the surface quality of square section die-less spinning[J].The International Journal of Advanced Manufacturing Technology,2015,80(9-12):1689-1700.
[6]Davidson M J,Balasubramanian K,Tagore G R N.Experimental investigation on flow-forming of AA6061 alloy-A Taguchi approach[J].Journal of Materials Processing Technology,2008,200(1-3):283-287.
[7]Xia Q X,Xie S W,Huo Y L,et al.Numerical simulation and experimental research on the multi-pass neck-spinning of non-axisymmetric offset tube[J].Journal of Materials Processing Technology,2008,206(1-3):500-508.
[8]Hauk S,Vazquez V H,Altan T.Finite element simulation of the flow-splitting-process[J].Journal of Materials Processing Technology,2000,98(1):70-80.
[9]夏琴香,王甲子,王映品,等.多楔带轮旋压增厚成形阶段金属流动规律分析[J].锻压技术,2009,34(6):101-106.Xia Q X,Wang J Z,Wang Y P,et al.Analysis on metal flow and deformation mechanism during thickening process of poly-wedge pulley spinning[J].Forging&Stamping Technology,2009,34(6):101-106.
[10]Jin J S,Deng L,Wang X Y,et al.A new rotary forming process for rim thickening of a disc-like sheet metal part[J].Journal of Materials Processing Technology,2012,212(11):2247-2254.
[11]Jin J S,Wang X Y,Li L.A sheet blank rotary forging process for disk-like parts with thickened rims[J].Journal of Mechanical Science and Technology,2016,30(6):2723-2729.
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