双辊摆辗大直径薄圆盘数值模拟分析及优化
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摘要
为了研究大直径薄圆盘双辊摆辗成形工艺,通过UG设计了闭式模具和浮动式模具两种不同的模型。以直径Φ505 mm、厚度5. 5 mm的圆盘为研究对象,利用Deform-3D数值模拟分析软件,对两种模具结构摆辗成形大直径圆盘件进行了分析,确定了闭式模具结构为较优方案。通过在闭式模具结构上进行正交试验,对摆辗成形工艺参数进行优化。结果表明,坯料初始温度、轧辊转速、下模进给速度以及工件和下模之间的摩擦系数对双辊摆辗成形大直径薄圆盘有着重要的影响。当坯料初始温度为950℃、轧辊转速为75 r·min~(-1)、下模进给速度为1 mm·s~(-1)、摩擦系数为0. 5时,圆盘成形质量较好。通过实际试验验证,获得了质量良好的工件。
In order to research double-roller rotary forging process for large diameter and thin disc,two different models of closed die and floating die were designed by UG. For the disc with diameter Φ500 mm and thickness 5 mm,two kinds of die structures were analyzed by numerical simulation analysis software Deform-3D,and the closed die was determined to be the optimized scheme. Then,the process parameters of doubleroller rotary forging were optimized by the orthogonal test on the closed die. The results show that the initial temperature of billet,the rotational speed of swing head,the feeding speed of lower die and the friction coefficient between workpiece and lower die have important influence on the forming of large diameter and thin disc by double-roller rotary forging. When the initial temperature of billet is 950 ℃,the rotational speed of swing head is 75 r·min~(-1),the feeding speed of lower die is 1 mm·s~(-1),and the friction coefficient of workpiece and lower die is 0. 5,the forming quality of the disc is better. Thus,the large diameter and thin disc with good quality is obtained by actual test.
In order to research double-roller rotary forging process for large diameter and thin disc,two different models of closed die and floating die were designed by UG. For the disc with diameter Φ500 mm and thickness 5 mm,two kinds of die structures were analyzed by numerical simulation analysis software Deform-3D,and the closed die was determined to be the optimized scheme. Then,the process parameters of doubleroller rotary forging were optimized by the orthogonal test on the closed die. The results show that the initial temperature of billet,the rotational speed of swing head,the feeding speed of lower die and the friction coefficient between workpiece and lower die have important influence on the forming of large diameter and thin disc by double-roller rotary forging. When the initial temperature of billet is 950 ℃,the rotational speed of swing head is 75 r·min~(-1),the feeding speed of lower die is 1 mm·s~(-1),and the friction coefficient of workpiece and lower die is 0. 5,the forming quality of the disc is better. Thus,the large diameter and thin disc with good quality is obtained by actual test.
引文
[1]胡正寰.零件轧制成形技术[M].北京:化学工业出版社,2010.Hu Z H.Technology of Rotary Metal Forming[M].Beijing:Chemical Industry Press,2010.
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[3]张猛,胡亚民.摆辗技术[M].北京:机械工业出版社,1998.Zhang M,Hu Y M.Pendulum Rolling Technology[M].Beijing:China Machine Press,1998.
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[6]张韶华,徐伟,张猛.双锥辊轴向轧机轧制原理及轧制力能参数计算[J].塑性工程学报,2005,12(3):18-21.Zhang S H,Xu W,Zhang M.Rolling principle of twin cone rollers axle-mill&calculating force and energy during axial rolling[J].Journal of Plasticity Engineering,2006,12(3):18-21.
[7]高波,朱春东,张易.双辊摆辗成形力能参数计算方法研究[J].锻压技术,2018,43(3):149-154.Gao B,Zhu C D,Zhang Y.Research on calculation of force and energy parameters for twin-roll swing rolling[J].Forging&Stamping Technology,2018,43(3):149-154.
[8]韩星会.冷摆辗成形机理与工艺参数优化设计[D].武汉:武汉理工大学,2010.Han X H.Forming Mechanism of Cold Rotary Forging and Process Parameters Optimization Design[D].Wuhan:Wuhan University of Technology,2010.
[9]Han X H,Hua L.3D FE modeling of cold rotary forging of a ring workpiece[J].Journal of Materials Processing Technology,2009,209(12):5353-5362.
[10]Oh H K,Choi S.A study on center thinning in the rotary forging of a circular plate[J].Journal of Materials Processing Technology,1997,66(1-3):101-106.
[11]张猛,张韶华,徐伟.双锥辊轴向轧机及轴向轧制技术[J].现代制造工程,2004,(9):59-60.Zhang M,Zhang S H,Xu W.Twin cone roll axial mill&axial rolling technology[J].Modern Manufacturing Engineering,2004,(9):59-60.
[12]徐伟,张锰.轴向轧制工艺及锥辊辗压机研究[J].锻压装备与制造技术,2002,37(6):22-23.Xu W,Zhang M.Research on axial rolling technology and cone roller press[J].Forging Equipment and Manufacturing Technology,2002,37(6):22-23.
[2]罗征志,曹建国,胡亚民.摆动辗压成形工艺研究现状及发展[J].锻压技术,2017,42(2):13-16.Luo Z Z,Cao J G,Hu Y M.Present research status and prospect of orbital forming process[J].Forging&Stamping Technology,2017,42(2):13-16.
[3]张猛,胡亚民.摆辗技术[M].北京:机械工业出版社,1998.Zhang M,Hu Y M.Pendulum Rolling Technology[M].Beijing:China Machine Press,1998.
[4]Zheng Y,Liu D,Yang Y.Investigation on metal flow during the hot axial closed die rolling process for titanium alloy discs[J].The International Journal of Advanced Manufacturing Technology,2016,87(9-12):2445-2458.
[5]刘钢,苑世剑.摆辗圆盘件中心变薄的预测及防止办法的有限元分析[J].塑性工程学报,1999,6(1):1-5.Liu G,Yuan S J.FEA of prediction and prevention of center thinning in rotary forging of a circular plate[J].Journal of Plasticity Engineering,1999,6(1):1-5.
[6]张韶华,徐伟,张猛.双锥辊轴向轧机轧制原理及轧制力能参数计算[J].塑性工程学报,2005,12(3):18-21.Zhang S H,Xu W,Zhang M.Rolling principle of twin cone rollers axle-mill&calculating force and energy during axial rolling[J].Journal of Plasticity Engineering,2006,12(3):18-21.
[7]高波,朱春东,张易.双辊摆辗成形力能参数计算方法研究[J].锻压技术,2018,43(3):149-154.Gao B,Zhu C D,Zhang Y.Research on calculation of force and energy parameters for twin-roll swing rolling[J].Forging&Stamping Technology,2018,43(3):149-154.
[8]韩星会.冷摆辗成形机理与工艺参数优化设计[D].武汉:武汉理工大学,2010.Han X H.Forming Mechanism of Cold Rotary Forging and Process Parameters Optimization Design[D].Wuhan:Wuhan University of Technology,2010.
[9]Han X H,Hua L.3D FE modeling of cold rotary forging of a ring workpiece[J].Journal of Materials Processing Technology,2009,209(12):5353-5362.
[10]Oh H K,Choi S.A study on center thinning in the rotary forging of a circular plate[J].Journal of Materials Processing Technology,1997,66(1-3):101-106.
[11]张猛,张韶华,徐伟.双锥辊轴向轧机及轴向轧制技术[J].现代制造工程,2004,(9):59-60.Zhang M,Zhang S H,Xu W.Twin cone roll axial mill&axial rolling technology[J].Modern Manufacturing Engineering,2004,(9):59-60.
[12]徐伟,张锰.轴向轧制工艺及锥辊辗压机研究[J].锻压装备与制造技术,2002,37(6):22-23.Xu W,Zhang M.Research on axial rolling technology and cone roller press[J].Forging Equipment and Manufacturing Technology,2002,37(6):22-23.