花键管增量式两轮冷滚轧工艺及数值模拟
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摘要
空心花键管作为传递力和扭矩的关键零件,常应用于定心精度要求高、传递转矩大或经常滑移的联接,在汽车以及各种车辆和装备制造业中应用非常广泛。冷滚轧精密成形属于少无切削加工工艺的一种,由于这种工艺不破坏零件表面纤维,因而具有齿面金属纤维连续性好、齿面强度高、耐磨性好、成形效率高和节约材料等优点。花键管冷滚轧精密成形过程不同于花键轴类零件,其坯料金属变形量大,成形过程较为复杂。因此生产工艺不同于传统花键的生产工艺,国内目前几乎还没有企业涉足。通过对轧制工艺方法发展趋势的分析,可以知道,对花键冷滚轧过程进行有限元分析,精确描述轧件金属流动规律、应力场、应变场和轧制力等,并在此基础之上对金属成形机理进行研究是十分必要的。
本文以增量式冷滚轧为研究对象,以空心花键管为研究对象的载体,分析研究了采用冷滚轧工艺成形空心花键管的可行性。结合实际情况,在理论分析的基础上进行模具设计、干涉检验和初步确定滚轧工艺条件参数,通过理论分析和仿真模拟,反复修正优化滚轧参数,使模拟结果的各项指标逐步趋于合理化,以求以较低成本和相对简单的设备和技术条件来实现非回转体的成形,提高滚轧成形件的质量和精度。
通过模拟仿真花键管冷滚轧过程,分析其坯料金属流动规律、应力应变场以及轧制力等,结果表明在参数条件为:坯料尺寸φ60×3.5mm、压下量:50%/30%/20%、摩擦系数0.12和滚轮转速36/rpm时成形性最好,金属塑性流动对称均匀,等效应力应变值也较小,轧制力较为合理。在模拟分析中,本文对于仍然存在的问题如工件打滑现象、工件尺寸长大和成形边界不够清晰等做出了分析研究,并提出了相应的解决方案。
最后,通过对现有试验设备Z28-80型滚丝机的改装,在其上进行试验,通过物理试验验证理论分析和模拟仿真所得优化滚轧参数的正确性和可靠性。
As the key parts for transmission of power and torque, the hollow spline tube is often applied in those spline connections, which needs high centering precision, high torque transfer capability or high transmission slip ratio. So, it is widely used in a variety of vehicles and equipment manufacturing industry. The precision cold roll forming is one kind of less or no cutting process. Due to its no destroying on the part surface fiber, it has a continuous metal tooth surface fiber, and many other advantages such as high wear resistance, high forming efficiency, material saving and so on. The spline tube differs greatly from the spline shaft parts in the cold roll forming process, which has a complex process with large blank deforming quantity. The production process is therefore different from the traditional production process of the spline shaft, and there is almost no relative research for the domestic enterprises. According to the analysis of development trends of rolling technology, we can see that it is necessary to accurately describe the Stress and Strain Field, the metal flow law and load prediction through Finite Element Analysis (FEA) on cold rolling for spline tube, as well as metal forming mechanism.
By taking incremental cold rolling as research object, and taking the hollow spline tube as the carrier of the research object, the paper analyzed the feasibility of forming of spline tube by adopting cold rolling process. According to practical situation, it carried out die designing, interference detection, parameter conditions preliminarily determine based on theoretical analysis. By the results of simulation, the paper modified the parameters repeatedly to make every indexes tend to be more reasonable in order to realize forming the high quality deformed parts by low-cost and simpler equipment and technical conditions.
Through FEA on cold rolling for spline tube and the analysis of the Stress and Strain Field, the metal flow law and load prediction, the result shows that the optimized parameters for the process are as follows: blank sizeφ60×3.5mm, press quantity 50%/30%/20%,friction coefficient 0.12 and speed of roller 36/rpm. Under this condition, the metal plastic flow is uniform, the values of equivalent stress and equivalent strain are smaller, and rolling force is more reasonable. Meanwhile, some issues in simulation were analyzed, and the respective solutions were proposed.
At the final, the physical experiment was carried on the retrofit of screw machine. The Experiment verification proves the correctness and reliability of above theoretical analysis and simulation.
本文以增量式冷滚轧为研究对象,以空心花键管为研究对象的载体,分析研究了采用冷滚轧工艺成形空心花键管的可行性。结合实际情况,在理论分析的基础上进行模具设计、干涉检验和初步确定滚轧工艺条件参数,通过理论分析和仿真模拟,反复修正优化滚轧参数,使模拟结果的各项指标逐步趋于合理化,以求以较低成本和相对简单的设备和技术条件来实现非回转体的成形,提高滚轧成形件的质量和精度。
通过模拟仿真花键管冷滚轧过程,分析其坯料金属流动规律、应力应变场以及轧制力等,结果表明在参数条件为:坯料尺寸φ60×3.5mm、压下量:50%/30%/20%、摩擦系数0.12和滚轮转速36/rpm时成形性最好,金属塑性流动对称均匀,等效应力应变值也较小,轧制力较为合理。在模拟分析中,本文对于仍然存在的问题如工件打滑现象、工件尺寸长大和成形边界不够清晰等做出了分析研究,并提出了相应的解决方案。
最后,通过对现有试验设备Z28-80型滚丝机的改装,在其上进行试验,通过物理试验验证理论分析和模拟仿真所得优化滚轧参数的正确性和可靠性。
As the key parts for transmission of power and torque, the hollow spline tube is often applied in those spline connections, which needs high centering precision, high torque transfer capability or high transmission slip ratio. So, it is widely used in a variety of vehicles and equipment manufacturing industry. The precision cold roll forming is one kind of less or no cutting process. Due to its no destroying on the part surface fiber, it has a continuous metal tooth surface fiber, and many other advantages such as high wear resistance, high forming efficiency, material saving and so on. The spline tube differs greatly from the spline shaft parts in the cold roll forming process, which has a complex process with large blank deforming quantity. The production process is therefore different from the traditional production process of the spline shaft, and there is almost no relative research for the domestic enterprises. According to the analysis of development trends of rolling technology, we can see that it is necessary to accurately describe the Stress and Strain Field, the metal flow law and load prediction through Finite Element Analysis (FEA) on cold rolling for spline tube, as well as metal forming mechanism.
By taking incremental cold rolling as research object, and taking the hollow spline tube as the carrier of the research object, the paper analyzed the feasibility of forming of spline tube by adopting cold rolling process. According to practical situation, it carried out die designing, interference detection, parameter conditions preliminarily determine based on theoretical analysis. By the results of simulation, the paper modified the parameters repeatedly to make every indexes tend to be more reasonable in order to realize forming the high quality deformed parts by low-cost and simpler equipment and technical conditions.
Through FEA on cold rolling for spline tube and the analysis of the Stress and Strain Field, the metal flow law and load prediction, the result shows that the optimized parameters for the process are as follows: blank sizeφ60×3.5mm, press quantity 50%/30%/20%,friction coefficient 0.12 and speed of roller 36/rpm. Under this condition, the metal plastic flow is uniform, the values of equivalent stress and equivalent strain are smaller, and rolling force is more reasonable. Meanwhile, some issues in simulation were analyzed, and the respective solutions were proposed.
At the final, the physical experiment was carried on the retrofit of screw machine. The Experiment verification proves the correctness and reliability of above theoretical analysis and simulation.
引文
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[2]刘仲文,赖周艺,张钰成.花键轴冷成形技术在中国的应用和发展.见:第九届全国塑性工程学术年会、第二届全球华人先进塑性加工技术研讨会论文集.2005(2):52-55
[3]杨金娥.花键管挤压成形规律研究:[硕士学位论文].武汉:武汉理工大学,2006
[4]胡正寰,张康生,王宝雨等.楔横轧零件成形技术与模拟仿真.北京:冶金工业出版社,2004
[5]杜惠萍.楔横轧精确成形关键问题的研究:[博士学位论文].北京:北京科技大学,2006
[6]张大伟.花键冷滚压工艺理论研究:[硕士学位论文].太原:太原科技大学,2007
[7]崔克天.花键冷滚轧有限元分析及弹塑性修正研究:[硕士学位论文].河南:河南科技大学,2006
[8]杨金娥,赵玉民,彭巍.花键管成形的力学分析.模具制造,2005,(10):24-26
[9]富壮.精密冷滚轧机床本体关键技术研究:[硕士学位论文].北京:燕山大学,2002
[10]王晓强,徐红玉,崔凤奎等.花键冷滚轧成形的有限元模拟.矿山机械,2007,35(7):139-141
[11]崔凤奎,李言,周彦伟等.渐开线花键轴冷滚轧工艺试验.农业机械学报,2006,37(12):189-192
[12]葛便京,杨有亮,冯春英等.渐开线花键轴冷滚轧轮的设计.工具技术,1998(7):24-26
[13]韩凤磷.渐开线花键冷滚轧工艺及设备研究:[硕士学位论文].北京:燕山大学,2005
[14]齐会萍.螺纹冷滚压理论语工艺参数研究:[硕士学位论文].太原:太原科技大学,2007
[15]彭舒杰,李道生,倪泽明等.渐开线螺旋花键冷滚轧工艺研究.金属成形工艺,1995,13(6):4-8
[16]杨建玺,崔凤奎,王晓强等.冷滚轧滚轮设计理论及实验修正.中国机械工程,2004,15(24):2168-2171
[17]赵玉民,杨金娥,彭巍.花键管挤压成形研究.机械制造,2006,44(503):41-42
[18]崔克天,崔凤奎,徐红玉等.滚轧轮设计的弹塑性修正试验研究.矿山机械,2006,34(4):127-129
[19]苏志鹏,崔凤奎,崔克天等.花键轴冷滚轧运动的数学模型研究与应用.矿山机械,2006,34(1):99-101
[20]张大伟,李永堂,付建华等.外花键冷滚压成形坯料直径计算.锻造,2007,2(20):56-59
[21]郑全刚.圆柱直齿小模数渐开线花键冷滚轧成形技术.汽车工艺与材料,1997,7:16-18
[22]吴修义.小模数渐开线花键滚轧轮的设计特点.机械工艺师,1997,1:15-16
[23]何枫.小模数渐开线花键滚轧轮的设计.工具技术,2001,35(2):23-25
[24]傅耀先.在滚丝机上冷轧加工小模数花键轴.工具技术,1999,33(8):16-18
[25]关雪梅,仇平,张立玲等.燕山大学学报,2004,28(1):49-51
[26]吕耀峰,崔凤奎,杨建玺等.冷滚轧渐开线花键成形原理及理论误差计算分析.设计与研究,2007:20-23
[27]张庆,富壮,孔祥东.冷滚轧机床同步机构的误差分析.中国机械工程,2002,13(12):1004-1009
[28]林晓磊,贺云龙,石磊.用冷滚轧方法加工小模数花键.中国机械工程师,2004,7:45-47
[29]薛文惠.在滚丝机上实现渐开线花键的滚轧加工.金属成形工艺,1999,17(3):46-51
[30]张大伟,李永堂,付建华.外花键冷滚压精密成形滚压接触面积的计算与仿真分析.太原科技大学学报,2007,28(1):64-68
[31]X.P.Fu and T.A.Dean.Past developments,current applications and trends in the cross wedge rolling process[C].International Journal of Machine Tools &Manufacture,1993,33(3):367-400
[32]V.V.Klepikov,A.N.Bodrov.Precise shaping of splined shafts in automobile manufacturing.Russian Engineering Research,2003,23(12):37-40
[33]ASM International Handbook Committee.Thread rolling(ASM Handbook Machining,vol.16).Materials Park,Ohio:ASM International,2001
[34]Joseph P.Domblesky,Feng Feng.Finite element modeling of external threading rolling.Wire Journal International,2001,34(10):110-115
[35]R.Mastunaga,T.Takemasu,T.Ozaki,et al.Spline rolling of deep drawn cups Adanced TechnologyofPlasticity,Vol.Ⅲ.Proceeding of the6th ICTP.Sept.19-241999,:2431-2436
[36]Donald E.Blue.Tooth Forming Rack With Replaceable Inserts.United States Patent,4028921,1977
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