环形零件辗扩成形工艺研究现状与发展趋势
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摘要
环形零件的辗扩成形工艺是一种局部加载连续成形工艺,成形过程中变形区材料在高温和外载荷作用下经历了非稳态、非线性的塑性变形。为探讨辗扩工艺中金属塑性变形机理,促进该工艺的改进、完善和推广新应用,国内外学者利用理论分析、数值模拟和试验研究等方法,对辗扩成形工艺过程、工艺参数及其对材料组织、性能的影响规律进行系统深入的研究。综合论述这种先进成形工艺研究现状;分析辗扩成形工艺参数理论与试验研究、环件辗扩过程组织演变规律数值模拟、环件辗扩成形过程成形/成性一体化调控等方面的发展趋势;针对目前环件辗扩成形工艺存在的流程长、能耗大、浪费材料等问题,提出环件短流程铸辗复合成形新工艺,并探讨这种新的短流程工艺的重点研究内容和推广应用前景。
Rolling forming process of ring parts is an advanced partial loading and continuous forming technology. Unsteady and nonlinear plastic forming occurs at the deformation zone during ring rolling under high temperature and load. For obtaining the deformation mechanics of the materials in ring rolling and promoting the improvement, perfect and application of this process, theoretical analysis, numerical simulation and experiments have been used to research the ring rolling process, process parameters and their effect rules on the microstructure and property of materials. The research status on this advanced forming technology is discussed. The developing trends on the theoretical and experimental study of rolling forming process, the numerical simulation of microstructure evolution in the process and the integrated regulation of forming and performance in rolling process are analyzed. Aiming at disadvantages such as longer production process, more energy consuming and wasting materials, the new cast-rolling forming technology of ring parts is put forward. The key scientific issues and application prospect of the new short process are investigated.
Rolling forming process of ring parts is an advanced partial loading and continuous forming technology. Unsteady and nonlinear plastic forming occurs at the deformation zone during ring rolling under high temperature and load. For obtaining the deformation mechanics of the materials in ring rolling and promoting the improvement, perfect and application of this process, theoretical analysis, numerical simulation and experiments have been used to research the ring rolling process, process parameters and their effect rules on the microstructure and property of materials. The research status on this advanced forming technology is discussed. The developing trends on the theoretical and experimental study of rolling forming process, the numerical simulation of microstructure evolution in the process and the integrated regulation of forming and performance in rolling process are analyzed. Aiming at disadvantages such as longer production process, more energy consuming and wasting materials, the new cast-rolling forming technology of ring parts is put forward. The key scientific issues and application prospect of the new short process are investigated.
引文
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[2]华林,黄兴高,朱春东.环件轧制理论和技术[M].北京:机械工业出版社,2001.HUA Lin,HUANG Xinggao,ZHU Chundong.Theory and technology of ring rolling[M].Beijing:China Machine Press,2001.
[3]YANG D Y,KIM K H,HAWKYARD J B.Simulation of T-section profile ring rolling by the 3-D rigid-plastic finite element method[J].International Journal of Mechanical Sciences,1991,33:541-550.
[4]华林,潘利波,李超.环件径轴向轧制的咬入条件分析[J].塑性工程学报,2007,14(5):102-105.HUA Lin,PAN Libo,LI Chao.Analysis of biting condition in radial-axial ring rolling[J].Journal of Plasticity Engineering,2007,14(5):102-105.
[5]ZHOU Guang,HUA Lin.Effects of axial rolls motions on radial–axial rolling process for large-scale alloy steel ring with 3D coupled thermo-mechanical FEA[J].International Journal of Mechanical Sciences,2012,59:1-7.
[6]郭良刚,杨合,金坚诚.环件径轴向轧制毛坯尺寸设计方法[J].机械工程学报,2010,46(24):1-9.GUO Lianggang,YANG He,JIN Jiancheng.Design method of blank sizes for radial-axial ring rolling[J].Journal of Mechanical Engineering,2010,46(24):1-9.
[7]欧新哲.金属环件热辗扩宏微观变形三维热力耦合有限元分析[D].西安:西北工业大学,2007.OU Xinzhe.Coupled thermo-mechanical 3D-FE analyses of macro-micro-deformation in hot ring rolling process[D].Xi’an:Northwestern Polytechnical University,2007.
[8]LEE K H.Advanced feasible forming condition for reducing ring spreads in radial–axial ring rolling[J].International Journal of Mechanical Sciences,2013,76:21-32.
[9]PARVIZI A,ABRINIA K.A two dimensional upper bound analysis of the ring rolling process with experimental and FEM verifications[J].International Journal of Mechanical Sciences,2014,79:176-181.
[10]HAN Xinghui,HUA Lin.A new cylindrical ring rolling technology for manufacturing thin-walled cylindrical ring[J].International Journal of Mechanical Sciences,2014,81:95-108.
[11]HAN Xinghui,HUA Lin.Plastic deformation behaviors and mechanical properties of rolled rings of 20CrMnTi alloy in combined radial and axial ring rolling[J].Materials and Design,2014(58):508-517.
[12]QIAN Dongsheng,ZHANG Zhiqiang,HUA Lin.An advanced manufacturing method for thick-wall and deep-groove ring-combined ring rolling[J].Journal of Materials Processing Technology,2013,213:1258-1267.
[13]陈孝庆,郭良刚,杨合,等.TC4钛合金锥形环辗轧坯料仿真优化设计[J].塑性工程学报,2014,21(2):25-31.CHEN Xiaoqing,GUO Lianggang,YANG He,et al.Study on blank optimization design of conical ring rolling process for TC4 titanium alloy by numerical simulation[J].Journal of Plasticity Engineering,2014,21(2):25-31.
[14]袁银良,华林,钱东升,等.内台阶截面环件轧制成形有限元模拟[J].模具制造,2006(5):8-11.YUAN Yinliang,HUA Lin,QIAN Dongsheng,et al.Finite element simulation to the rolling forming of inner-step-profile-section rong parts[J].Mold Manufacturing,2006(5):8-11.
[15]刘育华,李永堂,齐会萍,等.外台阶截面环形铸坯热辗扩成形工艺有限元模拟[J].锻压装备与制造技术,2013,48(4):81-83.LIU Yuhua,LI Yongtang,QI Huiping,et al.FEM simulation on hot ring rolling process of annular casting blank with outer stepped cross section[J].China Metalforming Equipment&Manufacturing,2013,48(4):81-83.
[16]YANG D Y,KIM K H,HAWKYARD J B.Simulation of T-section profile ring rolling by the 3-D rigid-plastic finite element method[J].International Journal of Mechanical Sciences,199l,33(7):541-550.
[17]KIM K H,SUKH G,HUBM Y.Development of the profile ring roiling process for large slewing rings of alloy steels[J].Journal of Materials Processing Technology,2007,187-188:730-733.
[18]许思广,曹起骧,连家创,等.环件轧制的热刚塑性耦合有限元分析[J].机械工程学报,1994,30(2):87-92.XU Siguang,CAO Qixiang,LIAN Jiachuang,et al.Coupled thermal and rigid-plastic finite element analysis of ring rolling[J].Chinese Journal of Mechanical Engineering,1994,30(2):87-92.
[19]GUO Lianggang,YANG He.Towards a steady forming condition for radial–axial ring rolling[J].International Journal of Mechanical Sciences,2011,53:286-299.
[20]王敏,杨合,郭良刚.钛合金大环热辗扩轧辊运动的数值仿真研究[J].稀有金属材料与工程,2012,41(1):14-18.WANG Min,YANG He,GUO Lianggang.Numerical study on motions of rolls in hot rolling of titanium alloy large rings[J].Rare Metal Materials and Engineering,2012,41(1):14-18.
[21]钱东升,华林.环件轧制三维有限元模拟中质量缩放方法的应用[J].塑性工程学报,2005,12(5):86-91.QIAN Dongsheng,HUA Lin.Application of mass sealing in simulation of ring rolling by three-dimansional finite element metdaod[J].Journal of Plasticity Engineering,2005,12(5):86-91.
[22]HAN Xinghui,HUA Lin.FE simulation and experimental research on cylindrical ring rolling[J].Journal of Materials Processing Technology,2014,214:1245-1258.
[23]HAN Xinghui,HUA Lin.Effect of friction on combined radial and axial ring rolling process[J].Tribology International,2014,73:117-127.
[24]KIM B.A dual-mesh approach to ring-rolling simulations with emphasis on remeshing[J].Journal of Manufacturing Processes,2013(15):635-643.
[25]国家自然科学基金委员会工程与材料学部.机械工程学科发展战略报告(2011-2020)[M].北京:科学出版社,2010.Engineering and Materials Department,National Natural Science Foundation of China.Mechanical engineering discipline development strategy report(2011-2020)[M].Beijing:Science Press,2010.
[26]ZHU S,YANG He.Investigation of deformation degree and initial forming temperature dependences of microstructure in hot ring rolling of TA15 titanium alloy by multi-scale simulations[J].Computational Materials Science,2012,65:221-229.
[27]王敏,杨合,郭良刚,等.基于3D-FEM的大型钛环热辗扩过程微观组织演变仿真[J].塑性工程学报,2008,15(6):76-80.WANG Min,YANG He,GUO Lianggang,et al.Simulation of microstructure evolution during hot rolling of large rings of titanium based on 3D-FEM[J].Journal of Plasticity Engineering,2008,15(6):76-80.
[28]ZHOU Guang,HUA Lin,LAN Jian,et al.FE analysis of coupled thermo-mechanical behaviors in radial-axial rolling of alloy steel large ring[J].Computational Materials Science,2010,50(1):65-76.
[29]钱东升,曾旭东,华林,等.304不锈钢大型环件细晶轧制实验[J].塑性工程学报,2012,19(2):60-65.QIAN Dongsheng,ZENG Xudong,HUA Lin,et al.Experimental study on fine-grain ring rolling of large scale 304 stainless steel[J].Journal of Plasticity Engineering,2012,19(2):60-65.
[30]GIORLEO L,CERETTI E,GIARDINI C.Energy consumption reduction in ring rolling processes:A FEM analysis[J].International Journal of Mechanical Sciences,2013,74:55-64.
[31]李永堂,齐会萍,杜诗文,等.一种金属环件短流程铸辗复合成形的方法:中国,ZL201010132486.6[P].2010-09-01.LI Yongtang,QI Huiping,DU Shiwen,et al.A method of casting-rolling compound forming of metal rings:China,ZL201010132486.6[P].2010-09-01.
[32]李永堂,齐会萍,刘志奇,等.一种利用铸坯辗扩成形大型环件的方法:中国,ZL201010132491.7[P].2010-09-08.LI Yongtang,QI Huiping,LIU Zhiqi,et al.A method of rolling forming large-scale rings use casting blank:China,ZL201010132491.7[P].2010-09-08.
[33]李永堂,齐会萍,李秋书,等.基于铸辗复合成形的42CrMo钢环坯铸造工艺与实验研究[J].机械工程学报,2013,49(20):49-54.LI Yongtang,QI Huiping,LI Qiushu,et al.Casting process and experimental research of 42CrMo ring blanks based on cast-rolling forming technology[J].Journal of Mechanical Engineering,2013,49(20):49-54.
[34]李永堂,齐会萍,付建华,等.42CrMo钢铸造环坯辗扩成形理论与工艺分析[J].机械工程学报,2014,50(2):77-85.LI Yongtang,QI Huiping,FU Jianhua,et al.Theoretical and process analyses on the cast-blank rolling forming of42CrMo bearing rings[J].Journal of Mechanical Engineering,2014,50(2):77-85.
[35]LI Yongtang,JU Li,QI Huiping,et al.Technology and experiment of 42CrMo bearing ring forming based on casting ring blank[J].Chinese Journal of Mechanical Engineering,2014,27(2):418-427.
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