车轮轮辋旋压成形技术研究
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摘要
目前铝合金轮毂作为汽车的安全性要求最高的零部件,其制造技术也在不断发展。锻造铝轮毂的质量最好,但成本高,效率低。近年来,欧美车轮行业逐步用锻旋铝合金轮毂取代传统的车轮生产工艺。轮毂的强旋成形是在热锻工艺基础上发展起来的,锻造制坯后进行旋压成形,提高了制造精度和力学性能。
与世界许多发达国家相比,我国在这一方面的研究相对滞后,轮毂强旋成形时的变形机理在理论上还不是很成熟,而且也找不到用来指导生产实践的具体理论。
根据轮毂旋压成形工艺,依据实际情况对轮毂旋压成形的边界、接触、运动轨迹、摩擦等条件进行确定,应用ABAQUS软件对成形过程进行三维有限元数值模拟,得出了成形过程中变形区应力、应变的分布规律。并分析了在壁厚减薄率一定时,不同旋轮进给率下坯料金属的径向变形、应力、应变及旋压力的变化规律。最后结合实验结果,分析了铝轮毂在强旋成形过程中产生的各种缺陷及原因。
将数值模拟结果与实验结果进行分析比较,为用数值模拟方法进一步深入研究铝合金轮毂强旋的成形机理和特点打下良好的基础,为类似复杂零件的精密成形提供了借鉴。
Currently aluminum alloy wheel as the highest security requirements for spare parts in a vehicle, its manufacturing technology is also constantly developing. Forged aluminum wheel has the best quality, however, the high cost and low efficiency. In recent years, Europe and the United States gradually replace the traditional production process by spinning and forging aluminum alloy wheels in wheel industry. Spin-forming wheel is developed on the hot forging process, spinning forming before forging billet, and improves the manufacturing precision and mechanical properties.
By contrast with many developed countries of the world, our studies have been lagged. Wheel spin-forming mechanism of the deformation in theory is not very mature, and can’t find the specific practice which can be used to guide the production practice.
According to forging and spinning technology, taking boundary condition, contact ,trajectory and friction into account in according with realistic processing of experiment, ABAQUS software is applied to 3D numerical simulation of power spinning of aluminum alloy wheel process and stress and strain distributions on shaping is considered. Rule of radial direction distortion of metal, variety of stress, strain and spinning force with the certain ratio of thinning and different roller feeding rate were analysis. In the end, associate with result of experiment, all kinds of vices of aluminum wheels’deforming were analysis as well as how to be.
Experimental results justifies numerical simulation, which sets up ground for further studying of mechanism and features of general power spinning of forging and spinning aluminum alloy wheels. It also provides experience for the precision forming of the similar complex parts and provides optimizing of process parameters with effective methods and reliable support.
与世界许多发达国家相比,我国在这一方面的研究相对滞后,轮毂强旋成形时的变形机理在理论上还不是很成熟,而且也找不到用来指导生产实践的具体理论。
根据轮毂旋压成形工艺,依据实际情况对轮毂旋压成形的边界、接触、运动轨迹、摩擦等条件进行确定,应用ABAQUS软件对成形过程进行三维有限元数值模拟,得出了成形过程中变形区应力、应变的分布规律。并分析了在壁厚减薄率一定时,不同旋轮进给率下坯料金属的径向变形、应力、应变及旋压力的变化规律。最后结合实验结果,分析了铝轮毂在强旋成形过程中产生的各种缺陷及原因。
将数值模拟结果与实验结果进行分析比较,为用数值模拟方法进一步深入研究铝合金轮毂强旋的成形机理和特点打下良好的基础,为类似复杂零件的精密成形提供了借鉴。
Currently aluminum alloy wheel as the highest security requirements for spare parts in a vehicle, its manufacturing technology is also constantly developing. Forged aluminum wheel has the best quality, however, the high cost and low efficiency. In recent years, Europe and the United States gradually replace the traditional production process by spinning and forging aluminum alloy wheels in wheel industry. Spin-forming wheel is developed on the hot forging process, spinning forming before forging billet, and improves the manufacturing precision and mechanical properties.
By contrast with many developed countries of the world, our studies have been lagged. Wheel spin-forming mechanism of the deformation in theory is not very mature, and can’t find the specific practice which can be used to guide the production practice.
According to forging and spinning technology, taking boundary condition, contact ,trajectory and friction into account in according with realistic processing of experiment, ABAQUS software is applied to 3D numerical simulation of power spinning of aluminum alloy wheel process and stress and strain distributions on shaping is considered. Rule of radial direction distortion of metal, variety of stress, strain and spinning force with the certain ratio of thinning and different roller feeding rate were analysis. In the end, associate with result of experiment, all kinds of vices of aluminum wheels’deforming were analysis as well as how to be.
Experimental results justifies numerical simulation, which sets up ground for further studying of mechanism and features of general power spinning of forging and spinning aluminum alloy wheels. It also provides experience for the precision forming of the similar complex parts and provides optimizing of process parameters with effective methods and reliable support.
引文
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37高卫民,王宏雁.UG软件在车身CAD建模中的应用,设计与计算,2000,(1):13-17
38庄茁.ABAQUS非线性有限元分析与实例.北京:科学出版社,2005:5-10
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47叶山益次郎,室田忠雄.スピニソタ゛加工法の研究(第一报)—绞クスピニソタ゛つひて——精密机械,1993,29(5):31-38
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73卫原平,王轶为.工艺参数对筒形件强力旋压过程的影响.模具技术,2000,4:12-16
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2滕焕波,冯再新,张志民.轻合金汽车轮毂的生产方法.轻合金加工技术,2006,(10):16-18
3王昕.铝合金汽车轮毂的生产方法.铝合金加工技术,2001,(4):38-39
4郑祥建,金龙兵,王国平,等.铝合金轮毂的生产和市场现状.铝合金加工技术, 2004(7):8-10
5史自力.中国汽车铝轮毂行业发展前景分析.经济经纬,2004,(3):61-65
6赖华清,范宏训.汽车铝合金轮毂的成形工艺.金属成形工艺,2002,(6):38-40
7陈适先,贾文铎.强力旋压工艺与设备.北京:国防工业出版社,1986:23-122; 16-19
8刘建华,杨合,李玉强.旋压技术基本原理的研究现状与发展趋势.重型机械,2002,3:1-4
9 Wang jiaxun. Constant Power and Self Synchronous System of Spinning Machine. Chinese Journal of Mechanical Engineering. 1993,(4):45-52
10李继贞,李志强,邱福兴,等.国产旋压设备最新动态.第九届全国旋压技术交流大会论文汇编.西安,2002:20-22
11张顺福,张存福.国产旋压设备的发展和应用.金属成形工艺,2003,21(1):1-9
12汪大年.金属塑性成形原理.北京:机械工业出版社,1986:85-132
13谢水生,王祖唐.金属塑性成形工步的有限元数值模拟.北京:冶金工业出版社,1997:1-15
14王祝堂.前景广阔的锻造铝合金轮毂.铸造纵横,2003,(6):22
15赵宪,吕炎,薛克敏.筒形件强旋三维弹塑性有限元分析.塑性工程学报,1995,2(4):46-5
16王祖唐,关廷栋.金属塑性成形理论.北京:机械工业出版社,1989:359-360
17周级华.金属塑性变形阻力.北京:机械工业出版社,1989:21-22
18朱有利,王先进,康永林,等.用有限变形弹塑性有限元法对金属塑性成型工艺的分析和优化.机械工程学报,1996,14(4):35-38
19孟凡中.弹塑性有限变形理论和有限元法.北京:清华大学出版社,1985:1-26
20赵云豪.旋压技术与应用.北京:北京有色金属研究总院加工工程研究中心,2002:1-74
21李东飞.基于PMAC下数控系统的研究与开发.[燕山大学工学硕士学位论文].2006:4-5
22刘才.金属成型非线形有限元模拟技术.燕山大学学报,1998,22(1):23-26
23王焕定,焦兆平,有限单元法基础.北京:高等教育出版社,2002:1-26
24赵经文,王宏钰.结构有限元分析.北京:科学出版社,2001:1-35
25朱伯芳.有限单元法原理与应用.北京:中国水利水电出版社,1998:56-59
26王勖成,邵敏.有限元单元法基本原理和数值方法.北京:清华大学出版社.1997:15-59
27 (日)山田嘉昭.非线性有限元基础.北京:清华大学出版社,1988:1-200
28苏岚,王先进,唐荻,等.有限元法处理金属塑性成型过程的接触问题.塑性工程学报,2000,7(4):12-15
29 Shiro Kobayashi. Metal Forming and the Finite Element Method. Oxford University Press, 1989:126-132
30胡忠.塑性有限元模拟技术的最新进展.塑性工程学报,1994,(9):1-11
31 J. S. Park. S. M. Hwang. Automatic Remeshing in Finite Element Simulation of Metal Forming Process by Guide Gride Method. Journal of Materials Processing Technology, 1991, 27:73-89
32 Tang L. Metal Formulation of Quasi-conforming Element and Huwashizu Principle. Comput stract, 1984, 19:247-250
33 Priit Podra, Soren Andersson. Finite element analysis wear simulation of a conical spinning contact considering surface topography. Wear, 1999, 224:13-21
34凌复华.有限元在应力分析中的应用.北京:国防工业出版社,1995:15-17
35董湘怀.材料成形计算机模拟.北京:机械工业出版社,2002:1-83
36洪如瑾.UG CAD快速入门指导.北京:清华大学出版社,2002:1-5
37高卫民,王宏雁.UG软件在车身CAD建模中的应用,设计与计算,2000,(1):13-17
38庄茁.ABAQUS非线性有限元分析与实例.北京:科学出版社,2005:5-10
39 www.blog.sina.com.cn/s/blog4a5f26cd01008i3.html
40石亦平,周玉蓉.ABAQUS有限元分析实例详解.北京:机械工业出版社,2006:2-11
41赵腾龙. ABAQUS 6.6在机械工程中的应用.北京:中国水利水电出版社,2007:9-15
42庄茁.ABAQUS有限元分析软件6.4版入门指南[M].北京:清华大学出版社,2004:7-11
43 www.jxcad.com.cn/simple/index.php?tid=11638
44叶山益次郎,工藤洋明.回转しごき加工の研究-Tube Spinningの解析. Journal of JSME. , 1966,69(568):631-639``
45 Y. Xu, S. H. Zhang, P. Li, etc. 3D rigid-plastic FEM numerical simulation on tube spinning. Journal of Materials Processing Technology, 2001, 113(1-3):710-713
46 Xue Kemin, Wang Zhen, Lu Yan, etc. Elastic-plastic FEM analysis and experimental study of diamentral growth in tube spinning. Journal of Materials Processing Technology. 1997, 69(1-3):172-175
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