TC4钛合金热应力校形工艺研究
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摘要
板料冲压成形在工业中应用广泛,精密钣金成形是制造行业共同追求的目标之一,尤其是在航空、航天、汽车等行业,钣金成形的精密要求更高。钣金经过常用成形方法成形后,精度达不到精密要求,而校形是提高钣金成形精度的有效方法。常用的校形方法有人工校形,时效校形,火焰校形和激光校形,这几种校形方法有其局限性。本文研究了一种新的热应力校形技术——高频感应加热热应力校形工艺。该工艺利用高频感应加热来代替火焰加热或激光加热来对板料进行热应力校形。论文的主要工作是开发高频感应加热热应力校形工艺的有限元预测模型,研究感应加热各参数对材料校形效果的影响规律,用热应力校形试验机对钛合金进行热应力校形试验。主要内容如下
(1)用电磁学、力学等知识进行了热应力校形的理论计算。
(2)开发出高频感应热应力校形工艺的磁-热-结构多场耦合有限元预测模型。在给定工艺参数前提下,用开发的有限元模型能够预测材料的校形结果。
(3)用热应力校形试验机进行了高频感应热应力校形试验研究,对有限元预测模型进行了验证,结果表明,有限元预测模型的预测精度是可以接受的,可以为生产提供参考。
(4)通过有限元模拟和试验研究相结合的方法,得出了主要工艺参数对TC4钛合金高频感应加热热应力校形效果的影响规律。
Sheet metal stamping is used in industry widely. One of the common pursuit target is precise sheet metal forming in manufacture field. Especially in aerospace and automobile industry, the precise requirement of sheet metal forming is more increasing. The precision of sheet metal can not meet the demand after sheet metal forming. So sizing is the effective method of improving sheet metal precision. The traditional approach to cause sheet metal forming are heat ageing , flame heating or laser, which have many limitations. A new hot sizing process——hot sizing process by high frequency induction is studied in this paper. This process heats by high frequency induction instead of flame or laser. Main research contents in this paper develop the FEA model of hot sizing by high frequency induction, and exploring laws of this process. Main research content as follow:
(1) Hot sizing theories are deduced according to electromagnetic field and mechanics theories, etc.
(2) The multiphysics coupled FEA model of hot sizing by high frequency induction has been developed. Under the condition of some certain technological parameters, hot sizing results can be predicted.
(3) Hot sizing experiment of TC4 titanium alloy by high frequency induction is carried out. The reliability of FEA model has been verified by experiment.
(4) By means of the compared method of numerical simulation and experimental research, the laws that main process parameters impact on hot sizing result is gotten.
(1)用电磁学、力学等知识进行了热应力校形的理论计算。
(2)开发出高频感应热应力校形工艺的磁-热-结构多场耦合有限元预测模型。在给定工艺参数前提下,用开发的有限元模型能够预测材料的校形结果。
(3)用热应力校形试验机进行了高频感应热应力校形试验研究,对有限元预测模型进行了验证,结果表明,有限元预测模型的预测精度是可以接受的,可以为生产提供参考。
(4)通过有限元模拟和试验研究相结合的方法,得出了主要工艺参数对TC4钛合金高频感应加热热应力校形效果的影响规律。
Sheet metal stamping is used in industry widely. One of the common pursuit target is precise sheet metal forming in manufacture field. Especially in aerospace and automobile industry, the precise requirement of sheet metal forming is more increasing. The precision of sheet metal can not meet the demand after sheet metal forming. So sizing is the effective method of improving sheet metal precision. The traditional approach to cause sheet metal forming are heat ageing , flame heating or laser, which have many limitations. A new hot sizing process——hot sizing process by high frequency induction is studied in this paper. This process heats by high frequency induction instead of flame or laser. Main research contents in this paper develop the FEA model of hot sizing by high frequency induction, and exploring laws of this process. Main research content as follow:
(1) Hot sizing theories are deduced according to electromagnetic field and mechanics theories, etc.
(2) The multiphysics coupled FEA model of hot sizing by high frequency induction has been developed. Under the condition of some certain technological parameters, hot sizing results can be predicted.
(3) Hot sizing experiment of TC4 titanium alloy by high frequency induction is carried out. The reliability of FEA model has been verified by experiment.
(4) By means of the compared method of numerical simulation and experimental research, the laws that main process parameters impact on hot sizing result is gotten.
引文
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[2]金泉林,刘晓飞,板热应力弯曲的试验研究,塑性工程学报,1999,6(1):12～19
[3]陆伟东,危行三,王笃其,船舶建造工艺,上海,上海交通大学出版社,1991年。
[4]张永康,激光加工技术,北京,化学工业出版社,2004年。
[5]纪卓尚,刘玉君,船体曲面钢板加工技术研究和展望,大连理工大学学报,2001,41(5):505～510。
[6]唐汉帆,船体曲板加工工艺现状及研究方向,舰船标准化工程师,2003,3:19～24。
[7]范平,陈明和,周兆锋等,板料无模成形技术——热应力成形,新技术新工艺,2007,11:62～64。
[8]刘顺洪,周龙早,李志远,激光诱发热应力成形技术,电加工与模具,2000,4:37～41。
[9] F. Vollertsen, S.Holzer.,Laser beam forming fundamentals and possible applications, VDI-Z, 1994.
[10]管延锦,季忠,孙胜等,激光诱发的热应力成形技术及其应用,航空工艺技术,1999,4:30～32。
[11]姜士林,赵长汉,感应加热原理与应用,天津,天津科技翻译出版公司出版,1993年。
[12] Adak M, Manda N R, Thermomechanical analysis of plates undergoing line heating using pseudolinear equivalent constant rigidity system, Journal of ship production, 2004, 20(2):84～89.
[13] Morinobu I, Kamichilra R, etc, Automation of plate bending process by line heating, Bulletin of the society of naval architects of Japan, 1994, 34(2): 120～125.
[14] Toshihatu Nomoto, Takuya Ohmori, Talcu Sutoh, etc,Development of simulation for plate bending by line-heating, Journal of the society of naval architects of Japan,1990,12, No.168: 527～535.
[15] Y. Ueda, Development of computer aided process planning system for plate bending by line heating: relation between the final form of the plate and the Inherent strain, Journal of Zosen Kyokai, 1991, Vol.170:577～586.
[16] Morinobu lshiyama, Ryoichi Kamichika, Automation of plate bending process by line heating, Journal of society of naval architecture Japan, l998,11: 12～18.
[17] Morinobu I, Yoshihiko T, Advanced line heating system applying FEM computer simulation, Bulletin of the society of naval architects of Japan, 1999, 39(2): 60～64.
[18] Jang C D, Moon S C, An Algorithm to determine heating lines for plate forming by line heating method, Journal of ship production, 1998,14(4): 238～245.
[19] Ueda Y, Murakawa H, Mohamed A, etc, Development of computer-aided process planning system for plate bending by line heating (report 1), Relation between final form of plate and inherent strain, Journal of ship production,1994,10(1): 59～67.
[20] Ueda Y, Murakawa H, Mohamed A, etc, Development of computer-aided process planning system for plate bending by line heating (report 2), Practice for plate bending in shipyard viewed from aspect of inherent strain, Journal of ship production, 1994, 10(4): 239～247.
[21] Ueda Y, Murakawa H, Mohamed A, etc, Development of computer-aided process planning system for plate bending by line heating (report 3), Relation between heating condition and deformation, Journal of ship production, 1994, 10(4): 248～257.
[22] Ueda Y, Murakawa H, Mohamed A, etc, Development of computer-aided process planning system for plate bending by line heating (report 4), Decision malting on heating conditions, location and direction, Transaction JWRI,1993, 22(2): 305～313.
[23] Shin J G, Ryu C H, Lee J H, etc, User-friendly, advanced line heating automation for accurate plate forming. Journal of ship production, 2003, 19(1): 8～15.
[24] Jang C D, Moon S C, An Algorithm to determine heating lines for plate forming by line heating method, Journal of ship production, 1998, 14(4): 238～245.
[25] Lee J S, Development of automatic marking generation system for plate forming by line heating, Journal of ship production, 1996,12(4): 247～253.
[26] Moshaiov A, RLatorre, Temperature distribution during plate bending by torch flame heating, Journal of ship research, 1985, 29(1): 1～11.
[27] Shin J G, Moshaiov A, Modified strip model for analyzing the line heating method-part1:elastic plates, Journal of ship research,1991, 35(2): 172～182.
[28] Moshaiov A, Shin J G, Modified strip model for analyzing the line heating method-part 2:thereto-elastic-plastic plates, Journal of ship research,1991, 35(3): 266～275.
[29] Shin J G, Woo J H, Analysis of heat transfer between the gas torch and the plate for the application of line heating, Journal of manufacturing science and engineering, 2003, 125(11):794～800.
[30] Koenig P C, Narita H, Baba K, Lean production in the Japanese shipbuilding industry, Journalof ship production, 2002,18(3): 167～174.
[31] Yu G, Anderson R J, Maekawa T, etc, Efficient simulation of shell forming by line heating, International journal of mechanical sciences, 2001, 43: 2349～2370.
[32] Thomas Hennige, Development of irradiation strategies for 3D-laser forming, Journal of materials processing technology, 2000(103): 102～108.
[33] Z. Hu, M. Labudovic, H. Wang, etc, Computer simulation and experimental investigation of sheet metal bending using laser beam scanning, International journal of machine tools and manufacture, 2001(41): 589～607.
[34]张杰刚,陈明和,板料激光成形技术,热加工工艺,2006,35(13):87～89。
[35]王秀凤,胡世光,陈光南,板料激光成形技术,锻压技术,1998(6):32～34。
[36]季忠,王忠雷,焦学健等,板料激光弯曲成形工艺参数优化设计,锻压技术,2002(6): 38～41。
[37]石永军,姚振强,沈洪,激光热应力板料成形角变形分析,南京航空航天大学学报,2005(11):99～103。
[38]季忠,吴诗惇，板料激光弯曲成形数值腄猓泄す?2001(10):953～956。
[39]季忠,吴诗惇，李淼泉，板料激光成形时的温度场研究，塑性工程学报,1997(6):14～18。
[40]陈敦军,龙丽,吴诗惇，板料激光曲线弯曲成形的数值腄猓泄倒こ?2003,14(13):1152～1155。
[41] Magee J, De Vin L J, Process planning for laser-forming, Journal of materials processing technology, 2002(120): 322～326.
[42] Thomas Hennige, Development of irradiation strategies for 3D-laser forming, Journal of materials processing technology, 2000(2):102～108.
[43] D.-J. Chen, Y.-B. Xiang, S.-C. Wu, Application of fuzzy neural network to laser bending process of sheet metal, Materials science and technology, 2002(6):677～680.
[44] K. Scully, Laser line heating, Journal of ship production, 1987,3(4):237～246.
[45] M. Geiger, Synergy of laser material processing and metal forming, Annals of the CIRP, 1994, 43(2):563～570.
[46] Kyrsanidi A K, Kennanidis T B, Pantelakis S G, Numerical and experimental investigation of the laser forming process, Journal of materials proceeding technology, 1999,87: 281～290.
[47] C.L. Yau, K.C.Chan, W.B.Lee, Laser bending of lead frame materials, Journal of materialsprocessing technology, 1998(82): 117～121.
[48] Y. Namba, Laser forming of metals and alloys, Proceedings of lamp, 1987(7): 601～606.
[49] H. Frackiewicz, W. Kalita, Z. Mucha, etc, Laser forming of sheets, VDI-berichte, 1990:317～328.
[50] Cheng P J, Lin S C, An analytical model to estimate angle formed by laser, Journal of materials processing technology, 2001(108): 314～319.
[51] P.J. Cheng, S.C. Lin, An analytical model for the temperature field in the laser forming of sheet metal, Journal of materials processing technology, 2000(101):260～267.
[52] Bao, Jiangcheng, Yao, Y. Lawrence, Study of edge effects in laser bending, American society of mechanical engineers, 1999(8): 941～948.
[53]赵凯华,陈熙谋,电磁学,北京,高等教育出版社,2003。
[54]贾起民,郑永令,陈暨耀,电磁学,北京,高等教育出版社,2001。
[55]倪光正,工程电磁场原理,北京,高等教育出版社,2002。
[56]秦曾煌,电工学,北京,高等教育出版社,1999。
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