轴承套圈冷辗扩成形过程的数值模拟研究
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摘要
环件冷辗扩是常温下借助于辗环机使环件产生壁厚减小、直径扩大、截面轮廓成形的塑性加工工艺。环件辗扩是轧制技术与机械零件制造技术的交叉和结合,具有材料利用率高、减少加工工序、提高工件质量和精度、降低零件的制造成本、节能和改善工作环境等优点,与传统加工工艺相比,具有重大的社会经济效益。
本文针对目前冷辗扩技术发展的现状和存在的问题,以深沟球轴承套圈的冷辗扩成形加工为研究对象,建立了环形件冷辗扩成形过程工艺仿真模型。研究了模具结构、进给速度、驱动辊转速以及材料参数等对环件冷辗扩的成形质量、力能参数以及轴向展宽等的影响规律,为环件冷辗扩生产工艺参数的合理确定提供了理论基础。本文的主要内容和得到的主要结论如下:
(1)有限元模型的建立。以大型非线性模拟软件ABAQUS为平台,采用弹塑性力学理论、大变形数值模拟技术,充分考虑环形件冷辗扩过程的三维变形、连续渐变、非对称、时变、非稳态等特征,有效处理环形件冷辗扩过程中的几何、物理和边界三重非线性的多参数耦合交互作用问题,建立了轴承套圈冷辗扩成形过程的有限元数值模拟模型。
(2)研究给出了轴承套圈冷辗扩成形过程有限元数值模拟中合理的进给速度、导向辊运动轨迹的确定与控制方法。根据咬入条件和锻透条件确定了轴承套圈冷辗扩成形过程中进给速度的设计公式。在模拟中采用随动式的导向辊,其运动轨迹为一段以驱动辊轴线为中心的圆弧。通过研究不同质量缩放系数对模拟结果的影响,确定了模拟中合理的质量缩放系数为10。
(3)研究了模具结构和加工工艺参数对轴承套圈成形的影响。合理的模具结构可以避免工件端面出现鱼尾现象,使套圈获得较好的端面质量,减小辗压成形后工件的机加工量。在成形初始阶段采用较大的进给速度,而在加工后期阶段采用较小的进给速度,有利于加工的稳定、提高成形的质量。随着驱动辊转速增大,所需的成形辗扩力减小,成形效果提高,但是易出现打滑,加工所需的冷辗机的功率增大,所以要根据生产的要求合理设计驱动辊转速。
(4)研究了材料性能参数与进给速度及其耦合作用对轴承套圈成形的影响。在模具加限制展宽结构情况下,研究了硬化指数、弹性模量和屈服强度等材料性能参数分别在0.10-0.40、100 GPa-400 GPa、50 MPa-400 MPa,均匀进给速度在1.0-4.0 mm/s范围内时,材料性能参数和进给速度对成形的耦合影响。
1)辗扩力随着进给速度的增大而增大;硬化指数对辗扩力的影响规律与不同硬化指数下材料的真实应力-应变曲线的变化规律基本一致;屈服强度在加工前期对辗扩力影响较大,后期影响较小;弹性模量对辗扩力的影响很小。
2)随着进给速度增大,材料在芯辊凹槽处成形的形状变差;随着硬化指数和弹性模量增大,轴承套圈端面的轴向展宽减小,随着进给速度增大,硬化指数和弹性模量对轴承套圈端面轴向展宽的影响减小;屈服强度对轴承套圈端面轴向展宽的影响较小。
3)进给速度越小,工件的最终形状越好,但随着进给速度增大,工件成形的不均匀程度得到改善;随着硬化指数增大,工件成形的最大变形量减小,变形均匀性提高。随着进给速度增大,硬化指数对工件内不均匀成形的影响减小;随着弹性模量增大,工件成形的最大等效塑性应变值增大,不均匀变形程度增大;屈服强度对工件成形的不均匀程度影响无明显规律。
4)进给速度对靠近内径处端面的变形量影响较大,随着进给速度增大,工件端面的等效塑性应变减小;随着硬化指数增大,工件端面的等效塑性应变减小,弹性模量和屈服强度对靠近外径处端面的应变量影响较大;随着进给速度增大,硬化指数、弹性模量和屈服强度对工件端面等效塑性应变影响减小。
5)进给速度增大,工件内表面等效塑性应变减小;硬化指数和屈服强度对工件内表面等效塑性应变影响较小。在沟槽处弹性模量的影响较大,且随着弹性模量的增大,沟槽处的等效应变增大。
Cold ring rolling technology is a cross and combination of rolling technology and mechanical manufacturing, which decreases the thickness of ring and enlarges the diameter of ring via the cold ring rolling mill. It has many advantages, such as high material utilization ratio, reduced procedures, high quality and precision, energy saving and improved working environment. Compared with traditional method, the ring rolling technology is of great social significance and economic performance.
Considering fully characteristics of cold ring rolling, simulation model is created to simulate the cold rolling of deep groove ball bearings. Influence of the parameters (such as mold structure, feed velocity, rotational speed and material parameters etc.) on roll force, axial spread and forming quality is studied. The main contents and conclusions of this paper are as follows:
(1) Based on ABAQUS software, a three-dimensional elastic-plastic FEM model is established. The elastic-plastic mechanics theory and numerical simulation technology of large deformation are adopted according to the different stages of the deforming process basing on the deforming mechanism of cold ring rolling.
(2) Proper feed velocity, motion track of guide roll and the mass scaling coefficient are determined. On basis of earlier work, designing formula of feed velocity is defined according to bite conditions and penetration conditions. The following motion guide rolls are adopted. The motion track is a segment of arc and the center is decided by the axis of drive roll, the distance of different times is computed and used to control the motion of guide rolls. Mass scaling can accelerate the simulation, so proper mass scaling coefficient is determined as 10 by comparison of the results under different mass scaling coefficients.
(3) Influence of the mold structure and process parameters is studied. Proper mould structure can not only avoid fishtail effect, but also give a result of high quality and less machining amount. In order to gain a stable process, higher feed velocity should be took at the beginning of the process, while lower feed velocity should be took latterly. The roll force decreases and the quality can be improved by increasing the rotational speed of the drive roll. But slipping happened more frequently and higher power cold ring rolling mill is needed. Therefore, proper rotational speed of drive roll should be determined according to the production requirements.
(4) Influence of the material property parameters, feed velocity and their coupling effect to forming process is studied. Limiting spread structure is adopted. when strain hardening exponent, Young's modulus and Yield strength are chosen respectively in the range of 0.10-0.40, 100GPa-400GPa, 50MPa-400MPa. Constant feed velocity is used and the scope is 1.1mm/s-4.0mm/s, influence of them to forming process is studied.
1) The roll force grows with the increase of feed velocity. The influence of strain hardening exponent to roll force is similar to true stress-strain wave under different strain hardening exponent. In the earlier stage, the roll force is easier to be influenced by Yield strength, but subsequently, the influence decreases. Young's modulus has little influence on the roll force.
2) When feed velocity increases, shaping effect turns worse. When strain hardening exponent and Young's modulus grow, side spread of the end face decreases, but when feed velocity increases, influence of them decreases. Side spread of the end face is hardly affected by Yield strength.
3) The work piece is easier to get good shape when feed velocity is low, but when feed velocity increases, the condition of homogeneous deformation is improved. While strain hardening exponent grows, the maximum deformation decreases and the condition of inhomogeneous deformation is improved. When feed velocity increases, the influence of strain hardening exponent decreases. When Young's modulus grows, the maximum deformation and the inhomogeneous deformation degree increases. Yield strength has little influence on the inhomogeneous deformation.
4) The deformation of end face is easier to be effected by feed velocity at the place close to inner surface. When feed velocity grows, the influence of strain hardening exponent, Young's modulus and Yield strength decreases.
5) When feed velocity increases, equivalent plastic strain of the inner surface decreases. Strain hardening exponent and Yield strength have little influence on the equivalent plastic strain of the inner surface. The equivalent plastic strain of the groove is affected by Young's modulus, and it grows when Young's modulus increases.
本文针对目前冷辗扩技术发展的现状和存在的问题,以深沟球轴承套圈的冷辗扩成形加工为研究对象,建立了环形件冷辗扩成形过程工艺仿真模型。研究了模具结构、进给速度、驱动辊转速以及材料参数等对环件冷辗扩的成形质量、力能参数以及轴向展宽等的影响规律,为环件冷辗扩生产工艺参数的合理确定提供了理论基础。本文的主要内容和得到的主要结论如下:
(1)有限元模型的建立。以大型非线性模拟软件ABAQUS为平台,采用弹塑性力学理论、大变形数值模拟技术,充分考虑环形件冷辗扩过程的三维变形、连续渐变、非对称、时变、非稳态等特征,有效处理环形件冷辗扩过程中的几何、物理和边界三重非线性的多参数耦合交互作用问题,建立了轴承套圈冷辗扩成形过程的有限元数值模拟模型。
(2)研究给出了轴承套圈冷辗扩成形过程有限元数值模拟中合理的进给速度、导向辊运动轨迹的确定与控制方法。根据咬入条件和锻透条件确定了轴承套圈冷辗扩成形过程中进给速度的设计公式。在模拟中采用随动式的导向辊,其运动轨迹为一段以驱动辊轴线为中心的圆弧。通过研究不同质量缩放系数对模拟结果的影响,确定了模拟中合理的质量缩放系数为10。
(3)研究了模具结构和加工工艺参数对轴承套圈成形的影响。合理的模具结构可以避免工件端面出现鱼尾现象,使套圈获得较好的端面质量,减小辗压成形后工件的机加工量。在成形初始阶段采用较大的进给速度,而在加工后期阶段采用较小的进给速度,有利于加工的稳定、提高成形的质量。随着驱动辊转速增大,所需的成形辗扩力减小,成形效果提高,但是易出现打滑,加工所需的冷辗机的功率增大,所以要根据生产的要求合理设计驱动辊转速。
(4)研究了材料性能参数与进给速度及其耦合作用对轴承套圈成形的影响。在模具加限制展宽结构情况下,研究了硬化指数、弹性模量和屈服强度等材料性能参数分别在0.10-0.40、100 GPa-400 GPa、50 MPa-400 MPa,均匀进给速度在1.0-4.0 mm/s范围内时,材料性能参数和进给速度对成形的耦合影响。
1)辗扩力随着进给速度的增大而增大;硬化指数对辗扩力的影响规律与不同硬化指数下材料的真实应力-应变曲线的变化规律基本一致;屈服强度在加工前期对辗扩力影响较大,后期影响较小;弹性模量对辗扩力的影响很小。
2)随着进给速度增大,材料在芯辊凹槽处成形的形状变差;随着硬化指数和弹性模量增大,轴承套圈端面的轴向展宽减小,随着进给速度增大,硬化指数和弹性模量对轴承套圈端面轴向展宽的影响减小;屈服强度对轴承套圈端面轴向展宽的影响较小。
3)进给速度越小,工件的最终形状越好,但随着进给速度增大,工件成形的不均匀程度得到改善;随着硬化指数增大,工件成形的最大变形量减小,变形均匀性提高。随着进给速度增大,硬化指数对工件内不均匀成形的影响减小;随着弹性模量增大,工件成形的最大等效塑性应变值增大,不均匀变形程度增大;屈服强度对工件成形的不均匀程度影响无明显规律。
4)进给速度对靠近内径处端面的变形量影响较大,随着进给速度增大,工件端面的等效塑性应变减小;随着硬化指数增大,工件端面的等效塑性应变减小,弹性模量和屈服强度对靠近外径处端面的应变量影响较大;随着进给速度增大,硬化指数、弹性模量和屈服强度对工件端面等效塑性应变影响减小。
5)进给速度增大,工件内表面等效塑性应变减小;硬化指数和屈服强度对工件内表面等效塑性应变影响较小。在沟槽处弹性模量的影响较大,且随着弹性模量的增大,沟槽处的等效应变增大。
Cold ring rolling technology is a cross and combination of rolling technology and mechanical manufacturing, which decreases the thickness of ring and enlarges the diameter of ring via the cold ring rolling mill. It has many advantages, such as high material utilization ratio, reduced procedures, high quality and precision, energy saving and improved working environment. Compared with traditional method, the ring rolling technology is of great social significance and economic performance.
Considering fully characteristics of cold ring rolling, simulation model is created to simulate the cold rolling of deep groove ball bearings. Influence of the parameters (such as mold structure, feed velocity, rotational speed and material parameters etc.) on roll force, axial spread and forming quality is studied. The main contents and conclusions of this paper are as follows:
(1) Based on ABAQUS software, a three-dimensional elastic-plastic FEM model is established. The elastic-plastic mechanics theory and numerical simulation technology of large deformation are adopted according to the different stages of the deforming process basing on the deforming mechanism of cold ring rolling.
(2) Proper feed velocity, motion track of guide roll and the mass scaling coefficient are determined. On basis of earlier work, designing formula of feed velocity is defined according to bite conditions and penetration conditions. The following motion guide rolls are adopted. The motion track is a segment of arc and the center is decided by the axis of drive roll, the distance of different times is computed and used to control the motion of guide rolls. Mass scaling can accelerate the simulation, so proper mass scaling coefficient is determined as 10 by comparison of the results under different mass scaling coefficients.
(3) Influence of the mold structure and process parameters is studied. Proper mould structure can not only avoid fishtail effect, but also give a result of high quality and less machining amount. In order to gain a stable process, higher feed velocity should be took at the beginning of the process, while lower feed velocity should be took latterly. The roll force decreases and the quality can be improved by increasing the rotational speed of the drive roll. But slipping happened more frequently and higher power cold ring rolling mill is needed. Therefore, proper rotational speed of drive roll should be determined according to the production requirements.
(4) Influence of the material property parameters, feed velocity and their coupling effect to forming process is studied. Limiting spread structure is adopted. when strain hardening exponent, Young's modulus and Yield strength are chosen respectively in the range of 0.10-0.40, 100GPa-400GPa, 50MPa-400MPa. Constant feed velocity is used and the scope is 1.1mm/s-4.0mm/s, influence of them to forming process is studied.
1) The roll force grows with the increase of feed velocity. The influence of strain hardening exponent to roll force is similar to true stress-strain wave under different strain hardening exponent. In the earlier stage, the roll force is easier to be influenced by Yield strength, but subsequently, the influence decreases. Young's modulus has little influence on the roll force.
2) When feed velocity increases, shaping effect turns worse. When strain hardening exponent and Young's modulus grow, side spread of the end face decreases, but when feed velocity increases, influence of them decreases. Side spread of the end face is hardly affected by Yield strength.
3) The work piece is easier to get good shape when feed velocity is low, but when feed velocity increases, the condition of homogeneous deformation is improved. While strain hardening exponent grows, the maximum deformation decreases and the condition of inhomogeneous deformation is improved. When feed velocity increases, the influence of strain hardening exponent decreases. When Young's modulus grows, the maximum deformation and the inhomogeneous deformation degree increases. Yield strength has little influence on the inhomogeneous deformation.
4) The deformation of end face is easier to be effected by feed velocity at the place close to inner surface. When feed velocity grows, the influence of strain hardening exponent, Young's modulus and Yield strength decreases.
5) When feed velocity increases, equivalent plastic strain of the inner surface decreases. Strain hardening exponent and Yield strength have little influence on the equivalent plastic strain of the inner surface. The equivalent plastic strain of the groove is affected by Young's modulus, and it grows when Young's modulus increases.
引文
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