粉末净成形压制工艺优化及三维复杂零件结构设计的数值模拟
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摘要
基于粉末连续体,运用MSC.Marc有限元软件对粉末净成形压制工艺进行优化,并对减重齿轮的结构设计进行数值模拟。通过与实验数据对比分析,验证了材料模型及仿真模拟的可靠性,在此基础上利用有限元软件研究分析压制方式、压制速度、摩擦系数、压制温度、保压时间等五组因素对压坯密度分布的影响。结果表明,压制方式是最显著的影响因子,采用双向压制、温压成形、低压制速度、小摩擦系数及保压方式的组合压制工艺能有效地改善粉体的密度分布。利用有限元软件对减重齿轮的结构进行优化设计,研究圆环高径比与压坯相对密度的关系,并确定减重孔最佳尺寸。结果表明,采用强制摩擦压制方式代替浮动压制方式,可有效改善孔洞薄壁处密度。此外,结合Workbench有限元软件对减重齿轮进行结构力学模拟仿真,分析薄壁处的受力情况,以满足对齿轮强度的要求。
The optimization of powder net-shape compacting technology and the structural design of weight reduction gear were simulated by MSC.Marc software based on the finite element method(FEM). The reliability and accuracy of the proposed FEM model were validated by the experimental results. The influences of compacting mode, compacting speed, friction coefficient, compacting temperature, and dwell time on the relative density distribution of compaction were studied by the finite element software. In the result,the combined compacting process can effectively improve the density distribution of powders as double-action pressing + warm compacting + low compacting speed + small friction coefficient + pressure maintaining. The optimal structure of weight reduction gear was carried out by the proposed FEM model, the relationship between the height-diameter ratio of spur gear and the relative density of compaction was studied, and the optimum size of weight reducing hole was determined. The results show that, the density on the thin wall of the hole can be effectively improved by using the forced friction pressing mode instead of floating pressing mode.The structural mechanics of weight reduction gear was simulated by Workbench software, the force condition on the thin wall was analyzed to reach the strength requirements of gear.
The optimization of powder net-shape compacting technology and the structural design of weight reduction gear were simulated by MSC.Marc software based on the finite element method(FEM). The reliability and accuracy of the proposed FEM model were validated by the experimental results. The influences of compacting mode, compacting speed, friction coefficient, compacting temperature, and dwell time on the relative density distribution of compaction were studied by the finite element software. In the result,the combined compacting process can effectively improve the density distribution of powders as double-action pressing + warm compacting + low compacting speed + small friction coefficient + pressure maintaining. The optimal structure of weight reduction gear was carried out by the proposed FEM model, the relationship between the height-diameter ratio of spur gear and the relative density of compaction was studied, and the optimum size of weight reducing hole was determined. The results show that, the density on the thin wall of the hole can be effectively improved by using the forced friction pressing mode instead of floating pressing mode.The structural mechanics of weight reduction gear was simulated by Workbench software, the force condition on the thin wall was analyzed to reach the strength requirements of gear.
引文
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[18]You M M,Pan S Y,Shen X P,et al.Current progress and prospect of numerical simulation in powder compaction.Powder Metall Ind,2017,27(4):49(尤萌萌,潘诗琰,申小平,等.粉末压制过程数值模拟的研究现状及展望.粉末冶金工业,2017,27(4):49)
[2]Cante J C,Riera M D,Oliver J,et al.Flow regime analyses during the filling stage in powder metallurgy processes:experimental study and numerical modelling.Granular Matter,2011,13(1):79
[3]Zhou Z Y,Li Y Y.Mechanical Modeling and Computer Simulation of Metal Powder Forming.Guangzhou:South China University of Technology Press,2011(周照耀,李元元.金属粉末成形力学建模与计算机模拟.广州:华南理工大学出版社,2011)
[4]Andersson D C,Lindskog P,Staf H,et al.A numerical study of material parameter sensitivity in the production of hard metal components using powder compaction.J Mater Eng Perform,2014,23(6):2199
[5]Bai C Y,He Y J,Xiang T T,et al.P/M forming technique for fuel control sleeve of diesel engine.Powder Metall Technol,2015,33(5):365(白才艳,何育嘉,项涛涛,等.柴油机油量控制套筒粉末冶金成形技术的研究.粉末冶金技术,2015,33(5):365)
[6]Wikman B,Bergman G,Oldenburg M,et al.Estimation of constitutive parameters for powder pressing by inverse modelling.Struct Multi Optim,2006,31(5):400
[7]Zhou Z P,Shen X P.Powder Metallurgy Machinery Parts and Practical Technology.Beijing:Chemical Industry Press,2005(周作平,申小平.粉末冶金机械零件使用技术.北京:化学工业出版社,2005)
[8]Huang Y Q,Shen X P,Pan S Y,et al.Numerical simulation of powder hot forging cam.Powder Metall Ind,2016,26(2):50(黄永强,申小平,潘诗琰,等.粉末热锻凸轮的数值模拟.粉末冶金工业,2016,26(2):50)
[9]Jung J M,Yoo J H,Jeong H J,et al.Three-dimensional characterization of SiC particle-reinforced Al composites using serial sectioning tomography and thermo-mechanical finite element simulation.Metall Mater Trans A,2014,45(12):5679
[10]Gao J Z.Plastic Forming Process and Die Design.Beijing:China Machine Press,2001(高锦张.塑性成形工艺与模具设计.北京:机械工业出版社,2001)
[11]Ludwig R,Apelian D,Leuenberger G.An NDEmethodology to predict density in green-state powder metallurgy compacts.J Nondestr Eval,2005,24(3):109
[12]Shen X P,Huang Y Q,Xu X D.Optimization design of the mould for oil-quantity-controlling sleeve of diesel engine.Mater Sci Eng Powder Metall,2016,21(4):618(申小平,黄永强,徐旭东.柴油机油量控制套筒的模具优化设计.粉末冶金材料科学与工程,2016,21(4):618)
[13]Shofman L A.Dependence of the density of metal-powder compacts on compaction pressure.Sov Powder Metall Met Ceram,1968,7(8):596
[14]Wang D G,Wu Y C,Jiao M H,et al.Finite element simulation of influence of different compacting processes on powder metallurgic products properties.Chin J Mech Eng,2008,44(1):205(王德广,吴玉程,焦明华,等.不同压制工艺对粉末冶金制品性能影响的有限元模拟.机械工程学报,2008,44(1):205)
[15]Sun L,Zhou C F,Wang H Y,et al.Microstructure and mechanical properties of powder metallurgy forging bilayer cam.Powder Metall Technol,2017,35(6):403(孙露,周春芳,王惠亚,等.粉末热锻双层材料凸轮的显微组织与力学性能研究.粉末冶金技术,2017,35(6):403)
[16]Fang W,He X B,Zhang R J,et al.Numerical simulation of powder volume fraction variation during powder injection molding filling flow process.Mater Sci Eng Powder Metall,2013,18(2):149(方伟,何新波,张瑞杰,等.粉末注射成形充模过程中粉体分布的数值模拟.粉末冶金材料科学与工程,2013,18(2):149)
[17]Zadeh H K,Jeswiet J,Kim I Y.Improvement in robustness and computational efficiency of material models for finite element analysis of metal powder compaction and experiment validation.Int J Adv Manuf Technol,2013,68(5-8):1785
[18]You M M,Pan S Y,Shen X P,et al.Current progress and prospect of numerical simulation in powder compaction.Powder Metall Ind,2017,27(4):49(尤萌萌,潘诗琰,申小平,等.粉末压制过程数值模拟的研究现状及展望.粉末冶金工业,2017,27(4):49)
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