镁合金板料热拉深成形实验与数值模拟研究
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摘要
镁合金作为目前实际应用中最轻的金属结构材料,在3C行业、汽车行业、国防、航空航天产品、人们日常的生活应用前景广泛。镁合金板料的冲压产品具有较好的力学性能和表面质量成为镁合金材料应用的一个趋势,而在冲压工艺中又以拉深工艺应用较广。由于拉深工艺过程是一个同时包含几何、材料、边界条件和力学等非线性条件于一体的极其复杂的过程,对镁合金拉深成形工艺的研究成为能否获得复杂镁合金塑性成形构件关键。
本文针对目前镁合金板料拉深成形工艺研究现状与实际需求,对镁合金板料热拉深成形过程的关键技术进行了实验研究、理论研究、数值模拟及二次开发研究。研究结果对指导镁合金产品设计、缩短产品开发周期、减少材料消耗和保证产品质量等具有科学意义和重要的实际应用价值。
主要内容如下:
设计制造了一套能自动控制拉深温度、拉深速度的镁合金板料热拉深成形的实验装置,为实现镁合金板料热拉深成形件产业化生产装置提供了参考;并用其对运用前景广阔的AZ31B、ME20M镁合金板料进行了热拉深成形物理实验,得到了两种镁合金板料热拉深成形最优工艺参数,为提出优化的镁合金板料热拉深成形工艺方案提供了依据。
利用光学金相显微镜对不同工艺参数下的AZ31B、ME20M镁合金板料热拉深成形圆筒件的金相组织结构进行了观察分析。结果表明:合理控制镁合金板料生产过程及镁合金板料热拉深成形过程工艺参数可以很好地控制镁合金板料拉深成形件金相组织结构的变化,使其具有较小晶粒组织,从而使镁合金拉深成形件具有良好的力学性能。
通过对镁合金板料进行热拉伸力学物理实验,首次提出了一个适合于镁合金板料热成形的含非常应变软化因子的高温流变应力数学模型;利用BP神经网络预测了镁合金板料热成形高温流变应力,将其预测结果与提出的数学模型预测结果、热拉伸力学物理实验结果进行了比较,进一步验证了本文提出的镁合金板料热成形高温流变应力数学模型的科学性、精确性;并用FORTRAN语言编程,在ABAQUS中进行了用户材料子程序VUMAT二次开发,将提出的高温流变应力数学模型加入到了数值模拟软件ABAQUS中,实现了在ABAQUS中加入并调用新的材料模型,使建立的材料模型更接近实际,拓展了ABAQUS软件的应用范围,提高了模拟精度。
合作设计制造了一套镁合金板料热拉深成形过程中凸凹模圆角处摩擦系数在线测量的实验装置,在综合考虑镁合金板料拉深成形过程中成形温度、压边力、润滑剂等因素的基础上,进行了镁合金板料热拉深成形凸凹模圆角处摩擦物理实验,分别提出了与成形工艺参数(成形温度、压边力)有关的凸凹模圆角处新的动态变化摩擦系数模型;并用FORTRAN语言编程,在ABAQUS中进行了用户子程序VFRIC二次开发,将提出的动态变化摩擦系数模型、修正的库仑摩擦模型相结合,加入到了数值模拟软件ABAQUS中,实现了在ABAQUS中加入真实摩擦边界条件的目的。
最后在ABAQUS软件中,分别通过不同方式获得了镁合金板料热拉深成形材料模型、摩擦边界条件,对镁合金板料热拉深成形规律进行了数值模拟研究,并与物理实验结果相比较。研究结果表明:本论文作者提出的镁合金高温流变应力模型、热拉深成形过程凸凹模圆角处的动态摩擦系数模型具有较强的科学意义与工程实用价值;利用二次开发将二者加入到ABAQUS模拟软件中去的方法是完全可行的;本文的研究成果在镁合金板料拉深成形件、乃至其它塑性成形产品生产实际中起到重要的指导意义,大大降低生产成本。
As the lightest structural material presently in the practical applications, magnesium alloys have high potential in 3C、automobile、products of national defense industry and aerospace、people's everyday life.The stamping products of magnesium alloy sheet metal have became a trend in use of magnesium alloy as its better mechanical properties and superficial qualities,but the deep drawing technology is used more wider in stamping technology.Because deep drawing technology is a extremely complicated process which includes nonlinear conditions of geometry、material、boundary conditions and mechanics and so on,study on deep drawing technology of magnesium alloy sheet metal become the key whether complicated plastic forming products can be aquired.
Pointing at the current research situation and actual requirements of deep drawing technology of magnesium alloy sheet metal,this paper carried out experimental research、theoretical research、numerical simulation and further development about the key technology during warm deep drawing of magnesium alloy sheet metal.The results have stronger scientific sense and important project application value in guiding the product design process of magnesium alloy, shortening the product development cycle,decreasing material consumption and guaranteeing product quality etc.
The main contents include as follows:
Design and construct a set of experimental installation of warm deep drawing of magnesium alloy sheet metal,which can control deep drawing temperature and velocity automaticly and supplys consults for realizing industrialized installation of magnesium alloy sheet metal products by warm deep drawing;Through the installation,experiments of warm deep drawing of AZ31B and ME20M were carded out to acquire the best parameters of technology,which supply basis to put forward optimal technology plan of magnesium alloy sheet metal warm deep drawing.
Utilizing optical microscope of metallographic,the metallographic organizations of warm deep drawing cylinder parts of magnesium alloy sheet metal were observed and analyzed.The results indicates:controlling parameters of technology reasonably during production of magnesium alloy sheet metal and sheet metal deep drawing jointly can control variation of metallographic organization to ensure the magnesium alloy sheet metal deep drawing parts own good mechanical properties because of little grain structure.
Through experimental studies on hot tensile of magnesium alloy sheet metal,a mathematical model of high temperature flow stress was put forward first which includes an inconstant strain softening factor suit to magnesium alloy sheet metal warm forming;BP neural network was also used to forecast high temperature flow stress of magnesium alloy sheet metal warm forming,the forecasting results of the mathematical model of high temperature flow stress and BP neural network and experimental results were compared to verify the science and accuracy of the mathematical model put forward by this paper;And the mathematical model was joined into ABAQUS through further development by user subroutine VUMAT using FORTRAN language,it realized an aim to join new material model into ABAQUS.
Design and construct a set of experimental equipment for measuring friction coefficient on line at the round comer of punch and die during magnesium alloy sheet metal warm deep drawing cooperatlely,and did the experiment under considering forming temperature,blank holding force,lubricant and so on,dynamically changing friction coefficient models about forming temperature and blank holding force at the round comer of punch and die were put forward separately;And the friction coefficient models and a modified Coulomb friction law were joined into ABAQUS through further development by user subroutine VFRIC using FORTRAN language, it realized an aim to join actual friction boundary conditions into ABAQUS.
Finally,through different methods to acquire material model and friction boundary conditions,numerical simulations of magnesium alloy sheet metal warm deep drawing were made in ABAQUS,and the results were compared with experimental results.It indicates:the mathematical model of magnesium alloy sheet metal high temperature flow stress and dynamically changing friction coefficient models at the round comer of punch and die during magnesium alloy sheet metal warm deep drawing put forward by this paper have stronger scientific sense and important project application value,and the way through further development to join them into ABAQUS is totally correct;the research results of this paper have done adequate preparations for guiding actually production of magnesium alloy deep drawing and other plastic forming products,decreasing production costs in practice greatly.
本文针对目前镁合金板料拉深成形工艺研究现状与实际需求,对镁合金板料热拉深成形过程的关键技术进行了实验研究、理论研究、数值模拟及二次开发研究。研究结果对指导镁合金产品设计、缩短产品开发周期、减少材料消耗和保证产品质量等具有科学意义和重要的实际应用价值。
主要内容如下:
设计制造了一套能自动控制拉深温度、拉深速度的镁合金板料热拉深成形的实验装置,为实现镁合金板料热拉深成形件产业化生产装置提供了参考;并用其对运用前景广阔的AZ31B、ME20M镁合金板料进行了热拉深成形物理实验,得到了两种镁合金板料热拉深成形最优工艺参数,为提出优化的镁合金板料热拉深成形工艺方案提供了依据。
利用光学金相显微镜对不同工艺参数下的AZ31B、ME20M镁合金板料热拉深成形圆筒件的金相组织结构进行了观察分析。结果表明:合理控制镁合金板料生产过程及镁合金板料热拉深成形过程工艺参数可以很好地控制镁合金板料拉深成形件金相组织结构的变化,使其具有较小晶粒组织,从而使镁合金拉深成形件具有良好的力学性能。
通过对镁合金板料进行热拉伸力学物理实验,首次提出了一个适合于镁合金板料热成形的含非常应变软化因子的高温流变应力数学模型;利用BP神经网络预测了镁合金板料热成形高温流变应力,将其预测结果与提出的数学模型预测结果、热拉伸力学物理实验结果进行了比较,进一步验证了本文提出的镁合金板料热成形高温流变应力数学模型的科学性、精确性;并用FORTRAN语言编程,在ABAQUS中进行了用户材料子程序VUMAT二次开发,将提出的高温流变应力数学模型加入到了数值模拟软件ABAQUS中,实现了在ABAQUS中加入并调用新的材料模型,使建立的材料模型更接近实际,拓展了ABAQUS软件的应用范围,提高了模拟精度。
合作设计制造了一套镁合金板料热拉深成形过程中凸凹模圆角处摩擦系数在线测量的实验装置,在综合考虑镁合金板料拉深成形过程中成形温度、压边力、润滑剂等因素的基础上,进行了镁合金板料热拉深成形凸凹模圆角处摩擦物理实验,分别提出了与成形工艺参数(成形温度、压边力)有关的凸凹模圆角处新的动态变化摩擦系数模型;并用FORTRAN语言编程,在ABAQUS中进行了用户子程序VFRIC二次开发,将提出的动态变化摩擦系数模型、修正的库仑摩擦模型相结合,加入到了数值模拟软件ABAQUS中,实现了在ABAQUS中加入真实摩擦边界条件的目的。
最后在ABAQUS软件中,分别通过不同方式获得了镁合金板料热拉深成形材料模型、摩擦边界条件,对镁合金板料热拉深成形规律进行了数值模拟研究,并与物理实验结果相比较。研究结果表明:本论文作者提出的镁合金高温流变应力模型、热拉深成形过程凸凹模圆角处的动态摩擦系数模型具有较强的科学意义与工程实用价值;利用二次开发将二者加入到ABAQUS模拟软件中去的方法是完全可行的;本文的研究成果在镁合金板料拉深成形件、乃至其它塑性成形产品生产实际中起到重要的指导意义,大大降低生产成本。
As the lightest structural material presently in the practical applications, magnesium alloys have high potential in 3C、automobile、products of national defense industry and aerospace、people's everyday life.The stamping products of magnesium alloy sheet metal have became a trend in use of magnesium alloy as its better mechanical properties and superficial qualities,but the deep drawing technology is used more wider in stamping technology.Because deep drawing technology is a extremely complicated process which includes nonlinear conditions of geometry、material、boundary conditions and mechanics and so on,study on deep drawing technology of magnesium alloy sheet metal become the key whether complicated plastic forming products can be aquired.
Pointing at the current research situation and actual requirements of deep drawing technology of magnesium alloy sheet metal,this paper carried out experimental research、theoretical research、numerical simulation and further development about the key technology during warm deep drawing of magnesium alloy sheet metal.The results have stronger scientific sense and important project application value in guiding the product design process of magnesium alloy, shortening the product development cycle,decreasing material consumption and guaranteeing product quality etc.
The main contents include as follows:
Design and construct a set of experimental installation of warm deep drawing of magnesium alloy sheet metal,which can control deep drawing temperature and velocity automaticly and supplys consults for realizing industrialized installation of magnesium alloy sheet metal products by warm deep drawing;Through the installation,experiments of warm deep drawing of AZ31B and ME20M were carded out to acquire the best parameters of technology,which supply basis to put forward optimal technology plan of magnesium alloy sheet metal warm deep drawing.
Utilizing optical microscope of metallographic,the metallographic organizations of warm deep drawing cylinder parts of magnesium alloy sheet metal were observed and analyzed.The results indicates:controlling parameters of technology reasonably during production of magnesium alloy sheet metal and sheet metal deep drawing jointly can control variation of metallographic organization to ensure the magnesium alloy sheet metal deep drawing parts own good mechanical properties because of little grain structure.
Through experimental studies on hot tensile of magnesium alloy sheet metal,a mathematical model of high temperature flow stress was put forward first which includes an inconstant strain softening factor suit to magnesium alloy sheet metal warm forming;BP neural network was also used to forecast high temperature flow stress of magnesium alloy sheet metal warm forming,the forecasting results of the mathematical model of high temperature flow stress and BP neural network and experimental results were compared to verify the science and accuracy of the mathematical model put forward by this paper;And the mathematical model was joined into ABAQUS through further development by user subroutine VUMAT using FORTRAN language,it realized an aim to join new material model into ABAQUS.
Design and construct a set of experimental equipment for measuring friction coefficient on line at the round comer of punch and die during magnesium alloy sheet metal warm deep drawing cooperatlely,and did the experiment under considering forming temperature,blank holding force,lubricant and so on,dynamically changing friction coefficient models about forming temperature and blank holding force at the round comer of punch and die were put forward separately;And the friction coefficient models and a modified Coulomb friction law were joined into ABAQUS through further development by user subroutine VFRIC using FORTRAN language, it realized an aim to join actual friction boundary conditions into ABAQUS.
Finally,through different methods to acquire material model and friction boundary conditions,numerical simulations of magnesium alloy sheet metal warm deep drawing were made in ABAQUS,and the results were compared with experimental results.It indicates:the mathematical model of magnesium alloy sheet metal high temperature flow stress and dynamically changing friction coefficient models at the round comer of punch and die during magnesium alloy sheet metal warm deep drawing put forward by this paper have stronger scientific sense and important project application value,and the way through further development to join them into ABAQUS is totally correct;the research results of this paper have done adequate preparations for guiding actually production of magnesium alloy deep drawing and other plastic forming products,decreasing production costs in practice greatly.
引文
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