金属成形热力耦合模拟与模具失效机制研究
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摘要
借助于Deform-3D软件对TC11钛合金齿轮盘的模锻生产过程进行了热力耦合模拟,并结合锻件生产与模具失效的统计数据,分析了锻模中3个易磨损区的主要失效机制。在1区,坯料与模具接触时间较长,随着界面传递热量的增加,模腔表面发生了软化,在高的机械压应力作用下该区域发生了粘着磨损;在3区,因氧化物颗粒和热机械疲劳裂纹产生的碎片滞留在锻模表面,并伴随着热锻过程的进行,碎片在模腔表面上发生密集流动,最终直接导致了锻模表面的磨粒磨损;而在2区,其工作条件不如3区和1区恶劣,由于锻模表面存在较大的热应力并在机械压应力的耦合作用下,锻模表面发生了热机械裂纹,但该裂纹并没有导致锻模材料的明显损耗。
The thermo-mechanical coupling simulation of TC11 titanium alloy gear disk was carried out by Deform-3 D software,and combined with the statistical data of forging production and die failure,the main failure mechanisms of forging die in three quick wearing regions were analyzed. In region 1,the contact time between the billet and die was long,with the increase of heat transfer at the interface,the surface of the die cavity was softened,and adhesive wear occurred in this area under high mechanical compression stress. In region 3,the debris caused by oxide particles and thermo-mechanical fatigue cracks was stuck on the surface of forging die,and with the hot forging process progressed,the debris flowed intensively on the surface of die cavity,which directly leaded to the abrasive wear on the surface of forging die. In region 2 where there was no such extreme conditions as in region 3 and region 1,due to the large thermal stress on the surface of forging die and the coupling of mechanical compression stress,the thermo-mechanical cracks occurred on the surface of forging die,but the cracks did not lead to the obvious loss of forging die material.
The thermo-mechanical coupling simulation of TC11 titanium alloy gear disk was carried out by Deform-3 D software,and combined with the statistical data of forging production and die failure,the main failure mechanisms of forging die in three quick wearing regions were analyzed. In region 1,the contact time between the billet and die was long,with the increase of heat transfer at the interface,the surface of the die cavity was softened,and adhesive wear occurred in this area under high mechanical compression stress. In region 3,the debris caused by oxide particles and thermo-mechanical fatigue cracks was stuck on the surface of forging die,and with the hot forging process progressed,the debris flowed intensively on the surface of die cavity,which directly leaded to the abrasive wear on the surface of forging die. In region 2 where there was no such extreme conditions as in region 3 and region 1,due to the large thermal stress on the surface of forging die and the coupling of mechanical compression stress,the thermo-mechanical cracks occurred on the surface of forging die,but the cracks did not lead to the obvious loss of forging die material.
引文
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[4]赵海宾.基于响应面汽车变速器螺旋伞齿轮精锻成形工艺优化[J].锻压技术,2016,41(4):10-13.ZHAO Haibin.Process optimization of precision forging for auto transmission spiral bevel gears based on response surface[J].Forging&Stamping Technology,2016,41(4):10-13.
[5]LANGE K,CSER L,GEIGER M,et al.Tool life and tool quality in bulk metal forming[J].CIRP Annals-Manufacturing Technology,1992,41(2):667-675.
[6]张骥超,韩非,黎聪,等.超高强钢辊压门槛零件切断模具磨损优化设计研究[J].塑性工程学报,2018,25(3):224-228.ZHANG Jichao,HAN Fei,LI Cong,et al.Study on optimization deisgn of punching die wear of roll-formed ultra-high strength steel rocker profile[J].Journal of Plasticity Engineering,2018,25(3):224-228.
[7]KANG J H,PARK I W,JAE J S,et al.A study on a die wear model considering thermal softening:(I)Construction of the wear model[J].Journal of Materials Processing Technology,1999,96(1-3):53-58.
[8]KIM D H,LEE H C,KIM B M,et al.Estimation of die service life against plastic deformation and wear during hot forging processes[J].Journal of Materials Processing Technology,2005,166:372-380.
[9]GRONOSTAJSKI Z,KASZUBA M,HAWRYLUK M,et al.A review of the degradation mechanisms of the hot forging tools[J].Archives of Civil and Mechanical Engineering,2014,14(4):528-539.
[10]马强,孙叶,刘瑞雪,等.不同回火温度对H13钢冲击韧度的影响[J].金属加工(热加工),2013,(15):33-34.MA Qiang,SUN Ye,LIU Ruixue,et al.Effect of different tempering temperature on impact toughness of H13 steel[J].Metal Working,2013,(15):33-34.
[11]谢晖,黄康,陈建新,等.双层不锈钢消声器壳体冲压工艺CAE分析与优化[J].塑性工程学报,2018,25(2):1-8.XIE Hui,HUANG Kang,CHEN Jianxin,et al.CAE simulation and optimization of double-layer stainless steel muffler shell stamping process[J].Journal of Plasticity Engineering,2018,25(2):1-8.
[12]宋宇,张丰收,皇涛,等.基于高温磨损的H13热作模具钢磨损规律和模型研究[J].塑性工程学报,2018,25(4):187-193.SONG Yu,ZHANG Fengshou,HUANG Tao,et al.Study on wear law and model of H13 hot working die steel based on high-temperature wear[J].Journal of Plasticity Engineering,2018,25(4):187-193.