高强度钢热冲压关键工艺试验研究与应用
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摘要
高强度钢板热冲压技术是一项既可减轻车体重量,又能提高碰撞安全性的新型制造技术,已得到国际汽车业界的广泛认同并推广使用。热冲压工艺过程中温度场、应力场、相变场相互耦合,在整个热冲压及淬火过程中扮演着非常重要的角色,其中温度因素是关键。高温条件下材料软化及温度瞬时变化易导致成形性缺陷及高温氧化等综合问题,对模拟热冲压板料和模具的传热过程,进行准确的零件成形性分析预测带来挑战。开展温度场相关热冲压工艺因素的试验研究,确定热冲压中关键工艺参数及边界条件,对热冲压工艺优化及准确实现产品成形性仿真预测具有重要的指导作用。
本论文从工艺原理、流程、材料性能、板料及模具温度场、硬度梯度热冲压工艺试验及仿真应用等温度场相关关键技术研究入手,对热冲压工艺及材料进行了系统研究。对比分析与温度相关的加热温度、保温时间、冷却速率工艺因素对淬火材料抗拉强度、硬度及微观组织性能指标的影响,引入KAHN撕裂韧性试验对热冲压关键工艺参数进行三因素四水平的正交试验优化试验研究,基于抗拉强度、伸长率、撕裂强度和单位面积裂纹形核功四个指标的综合评分方法,获得了基于工艺因素的热冲压高温淬火及中低温回火强韧性改进方案。
通过自主研发的热力模拟试验机研究了热冲压硼钢板材在马氏体转换温度之上的高温材料热力学性能,得到了不同应变率和温度下的高温应力-应变流动曲线；引入Norton-Hoff模型得到了高温热冲压硼钢22MnB5的流变应力5阶多项式拟合方程,实现热冲压热力多场耦合仿真分析；开展热冲压成形极限(Thermal Forming Limited Diagram,简称TFLD)试验研究,获得了成形温度区间的等温热成形极限三维曲面图,可用于热冲压温度场及成形性仿真模拟中断裂极限的评测；结合数值仿真研究了冷速调整下的简单V型热弯曲和U型热冲压成形过程温度变化规律,通过控制成形前板料冷速使板料达到最佳开始冲压温度600-700℃,可实现复杂深冲盒成形缺陷改善并确保性能满足热冲压生产需求。
基于温度场相关传热和氧化机理,对热冲压传热过程进行全面分析并开展工艺试验,获得了高温下热冲压钢板的氧化动力学方程；搭建了热冲压界面换热系数圆台试验平台,通过开发的IHCP反向建模流程获得了接触压强和氧化皮影响下的界面换热系数瞬态变化规律,围绕建立的高强度钢板热冲压温度场数值模拟仿真虚拟样机系统(King-Mesh Analysis System/Hot Forming),相关的传热模型和仿真流程有效实现热力耦合条件下热冲压温度场和成形性仿真功能。
本文还开展了硬度梯度热冲压金属复合材料工艺试验及仿真预测的应用性研究,搭建了热冲压分区冷却试验平台,获得了模具温度、空气间隙等工艺参数对硬度梯度复合材料性能的影响规律；运用量纲分析和反推法建立了热冲压材料硬度-强度-冷速指数模型,实现了温度场预测到产品性能预测的应用扩展。通过典型热冲压实验和仿真分析,证明了该模型可有效地实现产品最终硬度性能的预测,为具有强度定制性能的热冲压产品开发奠定基础。
Hot forming is a new manufacture technology for high strength steel. It can not only reduce the auto body weight, but also enhance the crash safety, which makes it recognized and widely used in the international automotive industry. Temperature is one of the key factors in the temperature-strain-phase transformation field coupling relationship, which plays an important role in the whole quenching and forming process. Due to the material softening and instantaneous temperature variation, some comprehensive problems occures at elevated temperatures, including formability defects and high-temperature oxidation,etc. The problems happened bring challenges to accurately simulating the heat transfer behaviour between blank and tool surface, as well as predicting the sheet formability. To obtain key process parameters and temperature boundary conditions in hot forming process, further process experimental researchs were executed and contribute to provide essential scientific instruction for optimizing the hot forming process and accurately predicting product formability.
In this paper, hot forming process and materials properties were investigated systematically by experiment and simulation. Temperautre field related key technology studies were involved on the process principle, process, materials of boron steel, the temperature field of blank and tool, gradient hardness hot forming technology. Focus on analyzing rules of the material tensile strength, hardness and microstructure properties factors which related to the temperature in hot forming (just like heating temperature, holding time, cooling rate), a series of fundamental tests were executed, KAHN tear toughness experiments with the L9(34) orthogonal design optimization plan were introduced to analysis effective strength and toughness key process parameters with four indexes (tensile strength, elongation, tear strength and UIE) base on comprehensive evaluation method. As a results, improved process parameters were suitable for quenching and low temperature tempering toughness improvement program.
To study the thermo-dynamic performance of hot forming boron steel above the martensitic transformation temperature, the independent self-developed thermal mechanical tensile machine was developed to investigate the flow stress and strain relationshipis of different strain rates and temperatures. Five order polynomial fitting equations for boron steel22MnB5rheological stress were obtained by the modified Norton-Hoff model at elevated temperatures, which can be used into the thermal-mechanical field coupling simulation of actual stamping process. Furthermore, thermal forming limit diagram (TFLD) expeiments were executed to get the3D forming limit surface diagram for22MnB5steel at elevated temperature, which providing fracture limit evaluation for formability prediction and temperature field simulation research. In addition, the temperature field experiments and simulation of V-part hot bending and U-part hot forming process were analyzed by controlling cooling rate. Formability experiment and simulation optimization research were conducted by typical deeping drawing parts through controlling the forming temperature in600-700℃, it indicated that the complex production formability improvement and performance meet the requirements in actual production by adjusting cooling rate so as to ensure start forming temperature at optimizing zone.
Based on heat transfering and the oxidation mechanism related to the temperature field, a comprehensive analysis of the heat transfer process and experiments were investigated, The high-temperature oxidation kinetics equations and special interface heat transfer coefficient (IHTC) cylinder platform was estabished for obtaining transient IHTC variation law, which considered the influence of pressure and the oxide layer factors through the IHCP reverse modeling optimization process. Relevant heat transfer laws were introduced to self-developed hot forming virtual prototype platform, named KMAS/HF (King-Mesh Analysis System/Hot Forming), to built the hot forming temperature field numerical simulation predict virtual prototype system, the coupled themo-mechanical numerical simulation studies for temperature field and formability was developed to prove the correctness and effectiveness based on relevant interface heat transfer models and simulation methods.
This paper also works on the fundamental simulation prediction study and practical experiment for hardness gradient hot forming metal composite materials. The process parameters influence law was investigated on the district cooling hot forming test platform, including tool temperature, air gap distance, etc. Based on the hot forming temperature field simulation platform, a hot forming material hardness-strength-cooling rate index model was established by dimensional analysis and inverse method for implementing the function extension, which not only the temperature field simulation but also the mechanical property prediction function were invovled. The typical shape of the hot forming through experimental and simulation analysis proved that the relevant model can effectively predict the final hardness properties in the actual hot forming process, as well as contributing to provide the foundation for speical hardness gradient property product development.
本论文从工艺原理、流程、材料性能、板料及模具温度场、硬度梯度热冲压工艺试验及仿真应用等温度场相关关键技术研究入手,对热冲压工艺及材料进行了系统研究。对比分析与温度相关的加热温度、保温时间、冷却速率工艺因素对淬火材料抗拉强度、硬度及微观组织性能指标的影响,引入KAHN撕裂韧性试验对热冲压关键工艺参数进行三因素四水平的正交试验优化试验研究,基于抗拉强度、伸长率、撕裂强度和单位面积裂纹形核功四个指标的综合评分方法,获得了基于工艺因素的热冲压高温淬火及中低温回火强韧性改进方案。
通过自主研发的热力模拟试验机研究了热冲压硼钢板材在马氏体转换温度之上的高温材料热力学性能,得到了不同应变率和温度下的高温应力-应变流动曲线；引入Norton-Hoff模型得到了高温热冲压硼钢22MnB5的流变应力5阶多项式拟合方程,实现热冲压热力多场耦合仿真分析；开展热冲压成形极限(Thermal Forming Limited Diagram,简称TFLD)试验研究,获得了成形温度区间的等温热成形极限三维曲面图,可用于热冲压温度场及成形性仿真模拟中断裂极限的评测；结合数值仿真研究了冷速调整下的简单V型热弯曲和U型热冲压成形过程温度变化规律,通过控制成形前板料冷速使板料达到最佳开始冲压温度600-700℃,可实现复杂深冲盒成形缺陷改善并确保性能满足热冲压生产需求。
基于温度场相关传热和氧化机理,对热冲压传热过程进行全面分析并开展工艺试验,获得了高温下热冲压钢板的氧化动力学方程；搭建了热冲压界面换热系数圆台试验平台,通过开发的IHCP反向建模流程获得了接触压强和氧化皮影响下的界面换热系数瞬态变化规律,围绕建立的高强度钢板热冲压温度场数值模拟仿真虚拟样机系统(King-Mesh Analysis System/Hot Forming),相关的传热模型和仿真流程有效实现热力耦合条件下热冲压温度场和成形性仿真功能。
本文还开展了硬度梯度热冲压金属复合材料工艺试验及仿真预测的应用性研究,搭建了热冲压分区冷却试验平台,获得了模具温度、空气间隙等工艺参数对硬度梯度复合材料性能的影响规律；运用量纲分析和反推法建立了热冲压材料硬度-强度-冷速指数模型,实现了温度场预测到产品性能预测的应用扩展。通过典型热冲压实验和仿真分析,证明了该模型可有效地实现产品最终硬度性能的预测,为具有强度定制性能的热冲压产品开发奠定基础。
Hot forming is a new manufacture technology for high strength steel. It can not only reduce the auto body weight, but also enhance the crash safety, which makes it recognized and widely used in the international automotive industry. Temperature is one of the key factors in the temperature-strain-phase transformation field coupling relationship, which plays an important role in the whole quenching and forming process. Due to the material softening and instantaneous temperature variation, some comprehensive problems occures at elevated temperatures, including formability defects and high-temperature oxidation,etc. The problems happened bring challenges to accurately simulating the heat transfer behaviour between blank and tool surface, as well as predicting the sheet formability. To obtain key process parameters and temperature boundary conditions in hot forming process, further process experimental researchs were executed and contribute to provide essential scientific instruction for optimizing the hot forming process and accurately predicting product formability.
In this paper, hot forming process and materials properties were investigated systematically by experiment and simulation. Temperautre field related key technology studies were involved on the process principle, process, materials of boron steel, the temperature field of blank and tool, gradient hardness hot forming technology. Focus on analyzing rules of the material tensile strength, hardness and microstructure properties factors which related to the temperature in hot forming (just like heating temperature, holding time, cooling rate), a series of fundamental tests were executed, KAHN tear toughness experiments with the L9(34) orthogonal design optimization plan were introduced to analysis effective strength and toughness key process parameters with four indexes (tensile strength, elongation, tear strength and UIE) base on comprehensive evaluation method. As a results, improved process parameters were suitable for quenching and low temperature tempering toughness improvement program.
To study the thermo-dynamic performance of hot forming boron steel above the martensitic transformation temperature, the independent self-developed thermal mechanical tensile machine was developed to investigate the flow stress and strain relationshipis of different strain rates and temperatures. Five order polynomial fitting equations for boron steel22MnB5rheological stress were obtained by the modified Norton-Hoff model at elevated temperatures, which can be used into the thermal-mechanical field coupling simulation of actual stamping process. Furthermore, thermal forming limit diagram (TFLD) expeiments were executed to get the3D forming limit surface diagram for22MnB5steel at elevated temperature, which providing fracture limit evaluation for formability prediction and temperature field simulation research. In addition, the temperature field experiments and simulation of V-part hot bending and U-part hot forming process were analyzed by controlling cooling rate. Formability experiment and simulation optimization research were conducted by typical deeping drawing parts through controlling the forming temperature in600-700℃, it indicated that the complex production formability improvement and performance meet the requirements in actual production by adjusting cooling rate so as to ensure start forming temperature at optimizing zone.
Based on heat transfering and the oxidation mechanism related to the temperature field, a comprehensive analysis of the heat transfer process and experiments were investigated, The high-temperature oxidation kinetics equations and special interface heat transfer coefficient (IHTC) cylinder platform was estabished for obtaining transient IHTC variation law, which considered the influence of pressure and the oxide layer factors through the IHCP reverse modeling optimization process. Relevant heat transfer laws were introduced to self-developed hot forming virtual prototype platform, named KMAS/HF (King-Mesh Analysis System/Hot Forming), to built the hot forming temperature field numerical simulation predict virtual prototype system, the coupled themo-mechanical numerical simulation studies for temperature field and formability was developed to prove the correctness and effectiveness based on relevant interface heat transfer models and simulation methods.
This paper also works on the fundamental simulation prediction study and practical experiment for hardness gradient hot forming metal composite materials. The process parameters influence law was investigated on the district cooling hot forming test platform, including tool temperature, air gap distance, etc. Based on the hot forming temperature field simulation platform, a hot forming material hardness-strength-cooling rate index model was established by dimensional analysis and inverse method for implementing the function extension, which not only the temperature field simulation but also the mechanical property prediction function were invovled. The typical shape of the hot forming through experimental and simulation analysis proved that the relevant model can effectively predict the final hardness properties in the actual hot forming process, as well as contributing to provide the foundation for speical hardness gradient property product development.
引文
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