CVD金刚石涂层拉拔模具参数优化仿真及试验研究
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摘要
随着国内大型装备制造业及空调制冷业的迅猛发展,我国在对铜线及铜管需求量增多的同时对其质量的要求也越来越高。它们不仅要保证足够的力学强度及刚度,还要有较高的表面光洁度和尺寸精度。在我国传统拉拔行业中,硬质合金模具应用最为广泛,但由于其自身材料性质使得模具在应用过程中磨损非常严重、精度难以保证、拉制质量差、模具消耗大、铜等原材料浪费严重,造成生产效率低,工人劳动强度大,严重制约了铜材拉拔行业效益和产品质量的提高。此外,大量模具硬质合金材料的消耗,直接导致国家战略物质钨资源的浪费。因此采用金刚石涂层技术,研究开发的具有优异性能(CVD金刚石薄膜具有十分接近天然金刚石的硬度、高的弹性模量、极高的热导率、良好的自润滑性和化学稳定性等优异性能)的新型CVD金刚石涂层拉拔模具,不仅能大幅度提高模具的使用寿命,显著提高生产效率和产品质量,减少原材料消耗,降低成本,给应用行业带来巨大的经济效益,而且对于有效减少钨资源的消耗,促进经济可持续发展,也具有重要意义。
本文通过弹塑性有限元法,利用非线性有限元分析软件分别对铜线材单、多道次及铜管空拉、固定短芯头拉拔和游动芯头拉拔过程进行有限元模拟,得到了各种拉拔条件下铜材及模具的轴向和径向应力分布,并通过不断改变模拟拉拔参数,及分析仿真结果得到各种拉拔条件下最佳的拉拔模具参数,最后对最佳的拉拔模具参数进行实际的拉拔试验研究,这对延长模具寿命、提高拉拔铜材的表面质量和尺寸精度及CVD金刚石涂层拉拔模具的推广应用有重要意义。
论文的具体研究内容如下:
1.采用非线性有限元分析软件对铜线材单道次拉拔过程进行有限元仿真,得到了拉拔过程中铜线及模具的轴向及径向应力分布规律,然后通过正交实验法研究了铜线不同压缩率时金刚石涂层拉拔模具参数(工作锥半角α,过渡圆弧半径R,定径带长度L)对铜材拉拔过程的影响,得到了最佳的拉拔模具孔型参数,及不同压缩率时各影响因素对铜材表面轴向残余应力和涂层模具最大等效应力的影响规律。最后实际拉拔试验表明,孔型参数优化后的金刚石涂层拉拔模具的工作寿命是硬质合金模具的10倍。
2.对铜线材多道次拉拔过程进行有限元仿真,得到了铜线及模具在各个道次的轴向及径向应力分布规律,并对比分析了生产用铜线多道次拉拔和双递减法所得铜材多道次拉拔对铜材等效应变、等效应力及残余应力的影响。这对实际生产中铜线多道次拉拔的道次优化有重要指导作用。
3.利用弹塑性有限元法对铜管的空拔过程进行有限元模拟,分析了空拔过程中铜管与模具的轴向及径向应力分布规律,并以此阐述了空拔铜管的缩径缺陷。然后采用正交实验法模拟研究了拉拔参数(工作锥半角α、过渡圆弧半径R、定径带长度L、摩擦系数μ、拉拔速度v)对铜管空拔的影响,并得到铜管一定减面率条件下的最佳拉拔参数及各因素对分析指标的影响。实际拉拔试验验证了铜管空拔有限元分析的正确。
4.借助有限元分析软件研究了金刚石涂层模具铜管短芯头的拉拔过程,得到了拉拔过程中铜管及模具的轴向、径向应力分布,并阐述了固定短芯头拉拔铜管的缩径缺陷,根据对模拟结果的分析,得到一定拉拔条件下最佳的模具配合参数,并比较分析了摩擦系数及金刚石涂层对拉拔后铜管尺寸精度的影响。应用试验表明,与硬质合金模具相比,模具配合参数优化后的金刚石涂层模具不仅可以大幅提高模具寿命,而且可保证拉拔后铜管的尺寸精度及表面光洁度。
5.通过有限元模拟研究了金刚石涂层模具铜管游动芯头的拉拔过程,分析了铜管及模具的轴向和径向应力分布,并通过正交实验法分析研究了外模参数(工作锥半角α、过渡圆弧半径R、定径带长度L)对铜材及涂层模具轴向应力的影响,并得到一定拉拔条件下最佳的外模参数。最后,对具有最佳孔型参数的外模进行实际的拉拔试验,与硬质合金模具相比,其产量和寿命都可至少提高8倍以上。
With the rapid development of large-scale equipment manufacturing industry and air-conditioning refrigeration, Chinese demand for copper tubes and wires with much higher qualities increases rapidly. It must not only guarantee adequate mechanical strength and stiffness, but also have a high surface finish and dimensional accuracy. In Chinese traditional drawing area, the cemented carbide drawing dies are widely used for their low manufacturing cost. But because of the material characteristic itself, it becomes abrade easily, so it is difficult to ensure the accuracy, the quality of drawn tubes, and it may also lead the more consuming of drawing dies and the wasting of copper, accordingly restricts the improvement of the productivity and the quality of drawn products. Meanwhile, the large quantities of consumption of cemented carbide drawing dies may directly result of the wasting of the national strategy of tungsten material. Therefore, the use of diamond coating technology to research and develop the new type of CVD diamond-coated drawing dies with excellent performance( CVD diamond films have the very similar hardness with the natural diamond, the high elastic modulus, the high thermal conductivity, the good self-lubricating and chemical stability and so on) can not only substantially increases the working lifetime of drawing dies, the productivity and quality of drawn products, reduce raw material consumption and costs, but also effectively decrease the consumption of tungsten resources and promote sustainable economic development.
In this paper, non-linear finite element analysis software was used to simulate copper wires with single-pass and multi-pass drawing, copper tubes with hollow sinking, fixed plug drawing and floating plug drawing. Based on the simulation results, we obtained the distribution of axial and radial stresses of drawing products and drawing dies with every drawing conditions. The optimal drawing die parameters were gained by changing the drawing parameters and analyzing the simulation results. Finally, the real drawing experiments were perform with these optimal drawing dies. It has a great significant for prolonging the working lifetime of drawing dies, improving the quality and accuracy of drawn products.
The main contents of the paper are as follows:
1. Using non-linear finite element analysis software analyzed the single-pass drawing process of copper wires, and obtained the distributions of axial stress and radial stress on wires and drawing dies; Then the orthogonal experiment was used to investigate the influence of parameters (the semi-angle of drawing diesα, the radius of transition arc R , the length of bearing part L)of diamond-coated drawing dies upon the copper wires drawing process with different compressibility. Based on the range analysis and variance analysis of the simulation results, the optimal parameters of diamond-coated drawing dies were gained, as well as the influence of experiment factors upon the axial residual stress of copper wires and the maximum equivalent stress of diamond-coated drawing dies. Finally the results of application experiments showed that the working lifetime of optimal diamond-coated drawing dies could be increased by a factor of 10 compared with the cemented carbide drawing dies.
2. In order to deeply investigate the influence of drawing passes on copper wires drawing process, the nonlinear FEM software was used to simulate the whole copper wires multi-pass drawing process, and analyzed the influence of the equivalent stress, equivalent strain and residual stress of copper wires multi-pass drawing for production and multi-pass drawing by double degressive method. The simulation results showed that with the same total elongation factor, the optimization of copper wires drawing passes can reduce the wire asymmetry deformation and the residual stress, improve the quality of drawn copper wires and promote the drawing productivity. It is of great significance for the real copper wires multi-pass drawing.
3. We used the nonlinear finite element software to simulate the whole copper tube hollow sinking process, and then analyzed distributions of the axial stress and radial stress, and explained the mechanism of drawn copper tubes diameter shrinking. The influence of drawing parameters (the semi-angle of drawing diesα, the transition arc radius R, the length of bearing part L, friction coefficientμ, drawing velocity v)on copper tubes hollow sinking was investigated by using orthogonal experiment. The optimal drawing parameters under certain reduction of area and the influence of factors on analysis indexes were obtained according to simulation results by range analysis and variance analysis. Furthermore, the optimal drawing parameters were simulated by FEM, and the simulation results confirmed the effectiveness of the orthogonal experiment in optimizing tubes drawing in hollow sinking.
4. In order to investigate the drawing process of diamond-coated drawing dies for copper tubes with fixed plug, the nonlinear finite element method was used to simulate the whole drawing process , the distributions of axial stress and radial stress were obtained, and the mechanism of the drawn copper tube diameter shrinking was explained. Based on the simulation results, the optimal matching parameters of diamond-coated drawing dies and fixed plugs were obtained under certain drawing conditions, and the influence of friction coefficients and diamond coating upon the diameter precision of drawn tubes were analyzed. Compared with cemented carbide drawing dies, the results of application experiments showed that diamond-coated drawing dies not only could prolong the working lifetime of drawing dies, but could improve the diameter precision and smoothness of drawn tubes.
5. We used the FEM simulaiton to investigate the influence of parameters(the semi-angle of conical dieα, the radius of transition arc R, the length of bearing part L ) of diamond-coated conical dies upon the deformation of copper tubes with floating plug drawing. Based on the simulation results, the distributions of the axial stress and radial stress of drawing tubes and dies are obtained. The relative influence of parameters of diamond-coated conical dies are systematically examined using the orthogonal experiment. The influence of conical die parameters and the optimal parameters of the diamond-coated conical die are obtained by range analysis and variance analysis under the compressibility of 26%. The drawing experiment confirms the effectiveness of the orthogonal experiment in optimizing tubes drawing conical dies. As compared with cemented carbide drwing dies, the working lifetime of the optimal diamond-coated drawing dies can be increased by a factor of 8.
本文通过弹塑性有限元法,利用非线性有限元分析软件分别对铜线材单、多道次及铜管空拉、固定短芯头拉拔和游动芯头拉拔过程进行有限元模拟,得到了各种拉拔条件下铜材及模具的轴向和径向应力分布,并通过不断改变模拟拉拔参数,及分析仿真结果得到各种拉拔条件下最佳的拉拔模具参数,最后对最佳的拉拔模具参数进行实际的拉拔试验研究,这对延长模具寿命、提高拉拔铜材的表面质量和尺寸精度及CVD金刚石涂层拉拔模具的推广应用有重要意义。
论文的具体研究内容如下:
1.采用非线性有限元分析软件对铜线材单道次拉拔过程进行有限元仿真,得到了拉拔过程中铜线及模具的轴向及径向应力分布规律,然后通过正交实验法研究了铜线不同压缩率时金刚石涂层拉拔模具参数(工作锥半角α,过渡圆弧半径R,定径带长度L)对铜材拉拔过程的影响,得到了最佳的拉拔模具孔型参数,及不同压缩率时各影响因素对铜材表面轴向残余应力和涂层模具最大等效应力的影响规律。最后实际拉拔试验表明,孔型参数优化后的金刚石涂层拉拔模具的工作寿命是硬质合金模具的10倍。
2.对铜线材多道次拉拔过程进行有限元仿真,得到了铜线及模具在各个道次的轴向及径向应力分布规律,并对比分析了生产用铜线多道次拉拔和双递减法所得铜材多道次拉拔对铜材等效应变、等效应力及残余应力的影响。这对实际生产中铜线多道次拉拔的道次优化有重要指导作用。
3.利用弹塑性有限元法对铜管的空拔过程进行有限元模拟,分析了空拔过程中铜管与模具的轴向及径向应力分布规律,并以此阐述了空拔铜管的缩径缺陷。然后采用正交实验法模拟研究了拉拔参数(工作锥半角α、过渡圆弧半径R、定径带长度L、摩擦系数μ、拉拔速度v)对铜管空拔的影响,并得到铜管一定减面率条件下的最佳拉拔参数及各因素对分析指标的影响。实际拉拔试验验证了铜管空拔有限元分析的正确。
4.借助有限元分析软件研究了金刚石涂层模具铜管短芯头的拉拔过程,得到了拉拔过程中铜管及模具的轴向、径向应力分布,并阐述了固定短芯头拉拔铜管的缩径缺陷,根据对模拟结果的分析,得到一定拉拔条件下最佳的模具配合参数,并比较分析了摩擦系数及金刚石涂层对拉拔后铜管尺寸精度的影响。应用试验表明,与硬质合金模具相比,模具配合参数优化后的金刚石涂层模具不仅可以大幅提高模具寿命,而且可保证拉拔后铜管的尺寸精度及表面光洁度。
5.通过有限元模拟研究了金刚石涂层模具铜管游动芯头的拉拔过程,分析了铜管及模具的轴向和径向应力分布,并通过正交实验法分析研究了外模参数(工作锥半角α、过渡圆弧半径R、定径带长度L)对铜材及涂层模具轴向应力的影响,并得到一定拉拔条件下最佳的外模参数。最后,对具有最佳孔型参数的外模进行实际的拉拔试验,与硬质合金模具相比,其产量和寿命都可至少提高8倍以上。
With the rapid development of large-scale equipment manufacturing industry and air-conditioning refrigeration, Chinese demand for copper tubes and wires with much higher qualities increases rapidly. It must not only guarantee adequate mechanical strength and stiffness, but also have a high surface finish and dimensional accuracy. In Chinese traditional drawing area, the cemented carbide drawing dies are widely used for their low manufacturing cost. But because of the material characteristic itself, it becomes abrade easily, so it is difficult to ensure the accuracy, the quality of drawn tubes, and it may also lead the more consuming of drawing dies and the wasting of copper, accordingly restricts the improvement of the productivity and the quality of drawn products. Meanwhile, the large quantities of consumption of cemented carbide drawing dies may directly result of the wasting of the national strategy of tungsten material. Therefore, the use of diamond coating technology to research and develop the new type of CVD diamond-coated drawing dies with excellent performance( CVD diamond films have the very similar hardness with the natural diamond, the high elastic modulus, the high thermal conductivity, the good self-lubricating and chemical stability and so on) can not only substantially increases the working lifetime of drawing dies, the productivity and quality of drawn products, reduce raw material consumption and costs, but also effectively decrease the consumption of tungsten resources and promote sustainable economic development.
In this paper, non-linear finite element analysis software was used to simulate copper wires with single-pass and multi-pass drawing, copper tubes with hollow sinking, fixed plug drawing and floating plug drawing. Based on the simulation results, we obtained the distribution of axial and radial stresses of drawing products and drawing dies with every drawing conditions. The optimal drawing die parameters were gained by changing the drawing parameters and analyzing the simulation results. Finally, the real drawing experiments were perform with these optimal drawing dies. It has a great significant for prolonging the working lifetime of drawing dies, improving the quality and accuracy of drawn products.
The main contents of the paper are as follows:
1. Using non-linear finite element analysis software analyzed the single-pass drawing process of copper wires, and obtained the distributions of axial stress and radial stress on wires and drawing dies; Then the orthogonal experiment was used to investigate the influence of parameters (the semi-angle of drawing diesα, the radius of transition arc R , the length of bearing part L)of diamond-coated drawing dies upon the copper wires drawing process with different compressibility. Based on the range analysis and variance analysis of the simulation results, the optimal parameters of diamond-coated drawing dies were gained, as well as the influence of experiment factors upon the axial residual stress of copper wires and the maximum equivalent stress of diamond-coated drawing dies. Finally the results of application experiments showed that the working lifetime of optimal diamond-coated drawing dies could be increased by a factor of 10 compared with the cemented carbide drawing dies.
2. In order to deeply investigate the influence of drawing passes on copper wires drawing process, the nonlinear FEM software was used to simulate the whole copper wires multi-pass drawing process, and analyzed the influence of the equivalent stress, equivalent strain and residual stress of copper wires multi-pass drawing for production and multi-pass drawing by double degressive method. The simulation results showed that with the same total elongation factor, the optimization of copper wires drawing passes can reduce the wire asymmetry deformation and the residual stress, improve the quality of drawn copper wires and promote the drawing productivity. It is of great significance for the real copper wires multi-pass drawing.
3. We used the nonlinear finite element software to simulate the whole copper tube hollow sinking process, and then analyzed distributions of the axial stress and radial stress, and explained the mechanism of drawn copper tubes diameter shrinking. The influence of drawing parameters (the semi-angle of drawing diesα, the transition arc radius R, the length of bearing part L, friction coefficientμ, drawing velocity v)on copper tubes hollow sinking was investigated by using orthogonal experiment. The optimal drawing parameters under certain reduction of area and the influence of factors on analysis indexes were obtained according to simulation results by range analysis and variance analysis. Furthermore, the optimal drawing parameters were simulated by FEM, and the simulation results confirmed the effectiveness of the orthogonal experiment in optimizing tubes drawing in hollow sinking.
4. In order to investigate the drawing process of diamond-coated drawing dies for copper tubes with fixed plug, the nonlinear finite element method was used to simulate the whole drawing process , the distributions of axial stress and radial stress were obtained, and the mechanism of the drawn copper tube diameter shrinking was explained. Based on the simulation results, the optimal matching parameters of diamond-coated drawing dies and fixed plugs were obtained under certain drawing conditions, and the influence of friction coefficients and diamond coating upon the diameter precision of drawn tubes were analyzed. Compared with cemented carbide drawing dies, the results of application experiments showed that diamond-coated drawing dies not only could prolong the working lifetime of drawing dies, but could improve the diameter precision and smoothness of drawn tubes.
5. We used the FEM simulaiton to investigate the influence of parameters(the semi-angle of conical dieα, the radius of transition arc R, the length of bearing part L ) of diamond-coated conical dies upon the deformation of copper tubes with floating plug drawing. Based on the simulation results, the distributions of the axial stress and radial stress of drawing tubes and dies are obtained. The relative influence of parameters of diamond-coated conical dies are systematically examined using the orthogonal experiment. The influence of conical die parameters and the optimal parameters of the diamond-coated conical die are obtained by range analysis and variance analysis under the compressibility of 26%. The drawing experiment confirms the effectiveness of the orthogonal experiment in optimizing tubes drawing conical dies. As compared with cemented carbide drwing dies, the working lifetime of the optimal diamond-coated drawing dies can be increased by a factor of 8.
引文
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