筒形件强力旋压动力学仿真研究
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摘要
筒形件强力旋压是一种综合了锻造、挤压、拉伸等工艺特点的先进加工工艺,已被广泛应用于国防军工和航空航天领域。随着旋压技术的发展和材料工业的进步,国内外对旋压制品的成型质量要求越来越高,同时也有越来越多的材料被应用于筒形件强力旋压中,因为每种材料的性能、尺寸均不相同,所以每次旋压一种新制品时,都需要重新设定旋压工艺参数。这些参数通常是科研人员凭借以往的加工经验,根据产品的设计要求来设定的。首先要设定若干组旋压工艺方案,并根据方案中的参数进行旋压工艺实验,依据实验结果对参数进行调整,如此反复方可最终确定工艺参数并进行相应的生产。这种工艺参数的设定方法不但造成了物质上的浪费,同时也耽误了生产时间。而且工艺实验会受到次数的限制,所以工艺实验所确定的参数往往并不是最佳的工艺参数。
通过动力学仿真模拟,在计算机上设定工艺参数,并进行模拟仿真实验,可以大大缩短旋压工艺实验所消耗的时间,并且不受经济成本和实验次数限制,可以最大程度的详细分析每个工艺参数对旋压制品成型质量的影响。从而有效的指导旋压工艺参数的设定,提高旋压制品的生产效率和成型质量。
尽管动力学仿真模拟具有很多优点,但在旋压前仍然需要设定一系列的工艺方案,而每组旋压方案中不同旋压工艺参数的设定,其主要依据是旋轮所受旋压力的大小,因此旋压力的准确求取成为能否合理设置旋压方案的关键。目前通常使用Thamasett算法对旋压力进行计算,但该算法与实测值偏差较大,本文在结合旋压工艺实验的基础上,针对Thamasett算法忽略旋轮前金属堆积而导致计算偏差的不足,根据其计算值和实测值所存在的偏差规律,修正了Thamasett算法,建立了新的旋压力模型。在应力方面,本文在运用胡克定律、圣维南原理等理论的同时,结合金属弹塑性成型理论,将筒形件的应力拆分成轴向、径向、切向三部分,并分别建立其平衡方程、变协调方程、边界条件方程和物性方程,从而建立了应力的数学模型。新的旋压力、应力数学模型可以将旋压工艺参数控制在一个更为合理的范围,为旋压工艺方案的合理确定提供了更为准确的依据。
本文以金属塑性成型有限元法为基础,以旋压力、应力新算法为依托,根据成型过程中材料的变形特点,选择ANSYS/LS-DYNA软件作为筒形件强力旋压动力学仿真模型的分析平台,在进行相应假设的同时,分别对筒形件强力旋压几何模型的建立、网格的划分、摩擦模型的选择、连接和约束的建立、收敛准则的选择、迭代求解等关键问题进行了研究。并最终建立了筒形件强力旋压的动力学仿真模型。
本文通过该动力学仿真模型研究了简形件在强力旋压过程中的变形情况,以及旋压力、应力、应变的变化情况,并以相同参数在旋压机上进行了旋压工艺实验。通过电测法获得了旋压成型过程中旋压力的变化规律,从工艺实验的角度验证了动力学仿真模型结果的可靠性。并针对不同方案旋制的旋压制品的缺陷进行了缺陷分析。并分析了主轴转速、旋轮进给量对旋压力的影响,进给量对应力、应变的影响,进给率对椭圆度、公称直径公差、壁厚公差的影响,以及毛坯尺寸精度对成型质量的影响。通过这些分析可使科研人员更准确的了解各旋压工艺参数的特性,并以此为依据进一步指导旋压工艺参数的设定,使其更加的合理化。
Power spinning process of cylindrical workpieces which synthesizes characters in forging, extruding and stretching is widely applied in national defense and aerospace field. With the development of spinning processing and material industry, higher demands on modeling quality of spinning products are placed at home and abroad. As more materials with different performance and dimension are applied in power-spinning of cylindrical workpieces, technological parameter needs to be reset in the spinning process of new products. The technological parameter is usually set by researchers depending on their working experiences and the design requirements of products. Spinning experiments are conducted for times to adjust the technological parameter according'to the experiment results. Then the technological parameter ultimately is ascertained and used for production. Therefore, money and production time are wasted. On account of the limitation of technological experiments in times of experiments, the final technological parameter is not always the most appropriate one.
Setting technological parameter on computers with dynamics simulation and performing simulation experiments can greatly shorten the time of technological experiments and analyze the effects of each technological parameter on modeling) quality of products. The economic cost and times of experiments are unconstrained. Applying dynamics simulation technique to spinning process is playing a guiding role in setting spinning process parameter and it can improve the production efficiency and modeling quality effectively.
Even though dynamics simulation has plenty of advantages, a series of spinning experiments are needed to be designed. The setting of technological parameter in each experiment is based on the spinning force. Therefore, calculating spinning force is the key to design a reasonable experiment. At present, Thamasett algorithm is Usually used to calculate spinning force. However, there is great deviation between the calculated values and measured values. Aiming at the problems of stress and spinning force modeling. Thamasett algorithm is corrected and a new spinning force model is built according to the deviation law between calculated values and measured values so as to make up the shortfall of the ignorance of metal accumulation before spinning wheels. In the part of stress, the author applies Hooke's law, Saint-Venant principle and elastic-plastic theory in the thesis. The stress of cylindrical workpieces is split in radial, axial and tangential direction, and the corresponding equilibrium equations. compatibility equations, boundary condition equations and constitutive equations are established to build the mathematical model of stress. The new spinning force and stress modelings can control technological parameters at a proper level. which is the base of setting reasonable process plans.
ANSYS/LS-DYNA software is chosen as an analysis platform based on the metal plastic forming finite element method, the new algorithm of spinning force and stress and the deformation characteristics of materials in the process of modeling. The hypothesis is tested. The establishment of the geometric model of power spinning process of cylindrical workpieces, the division of the grid, the choice of friction model, the setting-up of connection and constraint, the selection of convergence rule and the iterative solution are all researched and the dynamics simulation model of power spinning process of cylindrical workpieces is established.
This thesis studies the deformation of cylindrical workpieces in the power spinning process and changes of the spinning force and stress through simulation model. The spinning process experiments are carried out with the same technological parameters. The change rule of spinning force in the modeling process is obtained by electrometry. And defect analysis is done aiming at the defect of spinning products in different technical programs. The reliability of the results of dynamics simulation model is validated from the perspective of process experiments. The impacts of spindle speed and the feed rate of spinning wheels on spinning force, the influences of feed rate on stress, strain, circular degree, nominal diameter and wall thickness tolerance, and the effects of blank dimension on the modeling quality are analyzed. The analyses give researchers a better perspective on the characteristics of spinning technological parameters and provide guidance to the setting of parameters.
通过动力学仿真模拟,在计算机上设定工艺参数,并进行模拟仿真实验,可以大大缩短旋压工艺实验所消耗的时间,并且不受经济成本和实验次数限制,可以最大程度的详细分析每个工艺参数对旋压制品成型质量的影响。从而有效的指导旋压工艺参数的设定,提高旋压制品的生产效率和成型质量。
尽管动力学仿真模拟具有很多优点,但在旋压前仍然需要设定一系列的工艺方案,而每组旋压方案中不同旋压工艺参数的设定,其主要依据是旋轮所受旋压力的大小,因此旋压力的准确求取成为能否合理设置旋压方案的关键。目前通常使用Thamasett算法对旋压力进行计算,但该算法与实测值偏差较大,本文在结合旋压工艺实验的基础上,针对Thamasett算法忽略旋轮前金属堆积而导致计算偏差的不足,根据其计算值和实测值所存在的偏差规律,修正了Thamasett算法,建立了新的旋压力模型。在应力方面,本文在运用胡克定律、圣维南原理等理论的同时,结合金属弹塑性成型理论,将筒形件的应力拆分成轴向、径向、切向三部分,并分别建立其平衡方程、变协调方程、边界条件方程和物性方程,从而建立了应力的数学模型。新的旋压力、应力数学模型可以将旋压工艺参数控制在一个更为合理的范围,为旋压工艺方案的合理确定提供了更为准确的依据。
本文以金属塑性成型有限元法为基础,以旋压力、应力新算法为依托,根据成型过程中材料的变形特点,选择ANSYS/LS-DYNA软件作为筒形件强力旋压动力学仿真模型的分析平台,在进行相应假设的同时,分别对筒形件强力旋压几何模型的建立、网格的划分、摩擦模型的选择、连接和约束的建立、收敛准则的选择、迭代求解等关键问题进行了研究。并最终建立了筒形件强力旋压的动力学仿真模型。
本文通过该动力学仿真模型研究了简形件在强力旋压过程中的变形情况,以及旋压力、应力、应变的变化情况,并以相同参数在旋压机上进行了旋压工艺实验。通过电测法获得了旋压成型过程中旋压力的变化规律,从工艺实验的角度验证了动力学仿真模型结果的可靠性。并针对不同方案旋制的旋压制品的缺陷进行了缺陷分析。并分析了主轴转速、旋轮进给量对旋压力的影响,进给量对应力、应变的影响,进给率对椭圆度、公称直径公差、壁厚公差的影响,以及毛坯尺寸精度对成型质量的影响。通过这些分析可使科研人员更准确的了解各旋压工艺参数的特性,并以此为依据进一步指导旋压工艺参数的设定,使其更加的合理化。
Power spinning process of cylindrical workpieces which synthesizes characters in forging, extruding and stretching is widely applied in national defense and aerospace field. With the development of spinning processing and material industry, higher demands on modeling quality of spinning products are placed at home and abroad. As more materials with different performance and dimension are applied in power-spinning of cylindrical workpieces, technological parameter needs to be reset in the spinning process of new products. The technological parameter is usually set by researchers depending on their working experiences and the design requirements of products. Spinning experiments are conducted for times to adjust the technological parameter according'to the experiment results. Then the technological parameter ultimately is ascertained and used for production. Therefore, money and production time are wasted. On account of the limitation of technological experiments in times of experiments, the final technological parameter is not always the most appropriate one.
Setting technological parameter on computers with dynamics simulation and performing simulation experiments can greatly shorten the time of technological experiments and analyze the effects of each technological parameter on modeling) quality of products. The economic cost and times of experiments are unconstrained. Applying dynamics simulation technique to spinning process is playing a guiding role in setting spinning process parameter and it can improve the production efficiency and modeling quality effectively.
Even though dynamics simulation has plenty of advantages, a series of spinning experiments are needed to be designed. The setting of technological parameter in each experiment is based on the spinning force. Therefore, calculating spinning force is the key to design a reasonable experiment. At present, Thamasett algorithm is Usually used to calculate spinning force. However, there is great deviation between the calculated values and measured values. Aiming at the problems of stress and spinning force modeling. Thamasett algorithm is corrected and a new spinning force model is built according to the deviation law between calculated values and measured values so as to make up the shortfall of the ignorance of metal accumulation before spinning wheels. In the part of stress, the author applies Hooke's law, Saint-Venant principle and elastic-plastic theory in the thesis. The stress of cylindrical workpieces is split in radial, axial and tangential direction, and the corresponding equilibrium equations. compatibility equations, boundary condition equations and constitutive equations are established to build the mathematical model of stress. The new spinning force and stress modelings can control technological parameters at a proper level. which is the base of setting reasonable process plans.
ANSYS/LS-DYNA software is chosen as an analysis platform based on the metal plastic forming finite element method, the new algorithm of spinning force and stress and the deformation characteristics of materials in the process of modeling. The hypothesis is tested. The establishment of the geometric model of power spinning process of cylindrical workpieces, the division of the grid, the choice of friction model, the setting-up of connection and constraint, the selection of convergence rule and the iterative solution are all researched and the dynamics simulation model of power spinning process of cylindrical workpieces is established.
This thesis studies the deformation of cylindrical workpieces in the power spinning process and changes of the spinning force and stress through simulation model. The spinning process experiments are carried out with the same technological parameters. The change rule of spinning force in the modeling process is obtained by electrometry. And defect analysis is done aiming at the defect of spinning products in different technical programs. The reliability of the results of dynamics simulation model is validated from the perspective of process experiments. The impacts of spindle speed and the feed rate of spinning wheels on spinning force, the influences of feed rate on stress, strain, circular degree, nominal diameter and wall thickness tolerance, and the effects of blank dimension on the modeling quality are analyzed. The analyses give researchers a better perspective on the characteristics of spinning technological parameters and provide guidance to the setting of parameters.
引文
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