板材成形摩擦系数测试分析系统的研究
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摘要
金属板材成形在国民经济及压力加工领域中占有相当重要的地位，摩擦是金属薄板成形中重要的行为之一，它的存在大大地影响着板材的成形性能以及应力、应变的分布。它不仅造成能量消耗，还直接影响零件的成形极限、回弹和表面质量，因此金属板材塑性变形过程中摩擦系数的研究具有重要的现实意义。
本文针对板材轴对称件成形过程结合板材成形过程中的应力分布规律、边界条件的变化信息，并根据轴向力的平衡关系，从求解基本能量方程出发，对拉深力－行程曲线解析公式进行了新的推导，建立了精度更高的拉深力－行程曲线解析公式。
本文建立了板材成形摩擦系数测试分析系统，系统通过对板材拉深过程的监测，记录了拉深过程中的拉深力、拉深高度和压边力的数值，为摩擦系数的测定提供了数据的准备。
本文应用VB编程语言，基于最小二乘法原理给出摩擦系数的反求公式，结合金属板材的摩擦系数测定实验给出了更符合实际情况的金属板材塑性变形过程中的摩擦系数，为金属薄板成形的进一步研究提供了数据参考。
本文对压边力、润滑剂、材料性能参数等因素对摩擦系数的影响做了具体分析，对材料性能参数对摩擦系数的影响做了规律性的总结
The sheet metal deformation plays a very important role in national economy, and, at the same time, the friction is one of the important acts during metal processing, which is the important factor to the force performance and force transferring. It not only has a great impact on drawing force which leads to energy waste but also has a great impact in rebounding, deforming extent and surface quantity, therefore, the research in friction coefficient during metal plastic deformation has great important realistic significance.
The drawing force and punch depth curve analytic formula is given in this paper to meet the real friction condition including the analyzing of the stress distribution, the state and change information on the friction surface, and the regulation of friction as well.
This paper sets up the friction coefficient testing analysis research system. During the drawing processing the course of which is record by the system, it provides a very simple method for friction coefficient testing.
With combination of the method of least square fitting which can be fulfilled under the visual basic computer language, the friction coefficient data can be gained by handling the date which can be identified during the drawing experience and It provides effective reference data for the further research.
This paper gives some very realistic analyses on the impact factors of the friction coefficient which includes lubrication, the material properties parameters, and blank holding force
本文针对板材轴对称件成形过程结合板材成形过程中的应力分布规律、边界条件的变化信息，并根据轴向力的平衡关系，从求解基本能量方程出发，对拉深力－行程曲线解析公式进行了新的推导，建立了精度更高的拉深力－行程曲线解析公式。
本文建立了板材成形摩擦系数测试分析系统，系统通过对板材拉深过程的监测，记录了拉深过程中的拉深力、拉深高度和压边力的数值，为摩擦系数的测定提供了数据的准备。
本文应用VB编程语言，基于最小二乘法原理给出摩擦系数的反求公式，结合金属板材的摩擦系数测定实验给出了更符合实际情况的金属板材塑性变形过程中的摩擦系数，为金属薄板成形的进一步研究提供了数据参考。
本文对压边力、润滑剂、材料性能参数等因素对摩擦系数的影响做了具体分析，对材料性能参数对摩擦系数的影响做了规律性的总结
The sheet metal deformation plays a very important role in national economy, and, at the same time, the friction is one of the important acts during metal processing, which is the important factor to the force performance and force transferring. It not only has a great impact on drawing force which leads to energy waste but also has a great impact in rebounding, deforming extent and surface quantity, therefore, the research in friction coefficient during metal plastic deformation has great important realistic significance.
The drawing force and punch depth curve analytic formula is given in this paper to meet the real friction condition including the analyzing of the stress distribution, the state and change information on the friction surface, and the regulation of friction as well.
This paper sets up the friction coefficient testing analysis research system. During the drawing processing the course of which is record by the system, it provides a very simple method for friction coefficient testing.
With combination of the method of least square fitting which can be fulfilled under the visual basic computer language, the friction coefficient data can be gained by handling the date which can be identified during the drawing experience and It provides effective reference data for the further research.
This paper gives some very realistic analyses on the impact factors of the friction coefficient which includes lubrication, the material properties parameters, and blank holding force
引文
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2 邵荷生.摩擦与磨损.北京:煤炭工业出版社,1992:1-87
3 李生智.金属压力加工概论.北京:冶金工业出版社,1984:1-27,148-155
4 白柯芬.金属压力加工学.北京:冶金工业出版社,1988:35-78
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7 陆大雄.摩擦学.北京:北京出版社,1990:7-25
8 王松年.摩擦学原理及应用.北京:中国铁道出版社,1990:6-24
9 郑林庆.摩擦学原理.北京:高等教育出版社,1994:187-197
10 李晓焱.摩擦理论与摩擦系数:丹东纺专学报,1997,(3):34-36
11 林复生.简明摩擦学.重庆:重庆大学出版社,1987:1-10
12 Masami Konishi. Artificial Intelligence for Plastic Deformation.Journal of the Japan Society for Technology of Plasticity(JSTP),1993,(34): 345-351
13 Manabe,K. Artificial intelligence identification of process parameters and adaptive control system for deep-drawing process Journal of Materials Processing Technology,1998:421-426
14 Effects of process variables on V-die bending process of steel sheet International Journal of Mechanical Sciences,1998: 631-650
15 Chung Kwansoo,Ideal sheet forming with frictional constraints International Journal of Plasticity,2000: 595-610
16 Hassan,M.A. Friction aided deep drawing using newly developed blank-holder divided into eight segments International Journal of Machine Tools and Manufacture,2003: 637-646
17 Ken-ichi Manabe and M. Yang. Intelligent Technology on Sheet Metal Forming. Journal of the JSTP,1993,(34):398-404
18 H.J. Park et al.. A Fuzzy Self-Learning Control Method with Application to Hydroforming Processes. ASME Journal of Engineering for Industry,1995,117:197-303
Ken-ichi Kawai. Intelligent Spinning Technology. Journal of the JSTP,1993,
19 34(387):391-397
20 Lanzon,J.M. Characterising frictional behaviour in sheet metal forming Journal of Materials Processing Technology,1998:251-256
21 Kazuo Nose. Knowledge Engineering Applied to Automatic Flatness Control System for Aluminium Foil Rolling Mill. Journal of the JSTP,1993, 387 (34):358-362
22 H. B. Sim and M. C. Boyce. Finite Element Analysis of Real-time Stability Control in Sheet Forming Processes. ASME Journal of Engineering Materials and Technology,1992,114:181-188
23 全永昕.摩擦磨损原理.杭州:浙江大学出版社,1988:147-167
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28 Yamaguchi,K. Friction aided deep drawing of sheet metals using polyurethane ring and auxiliary metal punch. International Journal of Machine Tools and Manufacture,2002:633-642
29 Courvoisier. Analytical modelling of drawbeads in sheet metal forming Journal of Materials Processing Technology,American Society for Testing and Matesials,2003: 359-370
30 Murtagh,Adrian M. Surface friction effects related to pressforming of continuous fibre thermoplastic composites Composites Manufacturing,1995,169-175
31 Martinet,F.Application of ALE finite elements method to a lubricated friction model in sheet metal forming International Journal of Solids and Structures,2000,4005-4031
32 Leu,Daw-Kwei,Prediction of the maximum drawing load in the cup-drawing process of sheet metals Journal of Materials Processing Technology,1997,256-261
33 Hodgson,P.D. Effect of membrane stress on surface roughness changes in sheet forming,2002,610-617
34 Song Yuquan and Zhao Jun. A Mechanical Analysis of the Superplastic Free Bulging of Metal Sheet. Material SciencEngineering,1986,84:111-122
35 A. S. Wifi. An Incremental Complete Solution of the Stretch Forming and Deep Drawing of a Circular Blank Using a Hemispherical Punch. Int. J,1976,18:23-31
36 徐树成.板成形中摩擦系数测定的研究进展.塑性工程学报,1997,(2):39-44
37 徐树成.薄板深冲成形过程中摩擦系数的测定.塑性工程学报,2000,(4):25-28
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39 罗亚军.板材拉深成形智能化控制过程中摩擦系数的识别.锻压技术,2001,(2):38-42
40 汪锐.板材拉深成形过程中摩擦条件与压边力设定关系研究.锻压技术2001,(6):22-26
41 何丹农.拉深用润滑剂的摩擦系数和压边力的关系研究.摩擦学学报,2000,(3):34-37
42 赵军.圆锥形零件拉深成形智能化研究.[哈尔滨工业大学博士论文],1997:1,17-46
43 赵军, 曹宏强, 马丽霞等.锥形件智能化拉深实验系统.中国机械工程学会锻压学会第五届冲压学术年会论文集.南昌:江西高校出版社,1998:136-139
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47 张双杰, 马丽霞, 张金泉等. 圆锥形件拉深成形时悬空侧壁应力分布的实验研究,秦皇岛:燕山大学报,1999(23)140-142
48 王祖唐.金属塑性成形理论: 北京:机械工业出版社,1989:1
49 胡士光, 陈鹤峥.板料冷压成形原理(修订版).北京:国防工业出版社,1989:68-97
50 王川涛.金属成形的各种方法简介.金属成形工艺,1986,4(2):56-60
51 Ε.Π.翁克索夫, W.约翰逊, 工腾英明.金属塑性变形理论.王仲仁译:北京:机械工业出版社,1992:393-461
52 R. D. Wood. The Finite Element Method and Sheet Metal Forming. Sheet Metal Ind,1981,8(58):561-567
53 N.-M. Wang,B. Budiansky. Analysis of Sheet Metal Stamping by a Finite Element Method. ASME J. Appl.Mech,1978,45:73-82
54 M. Gotoh,FIshise. A Finite Element Analysis of Rigid-plastic Deformation of the Flange in a Deep-Drawing Process Based on a Fourth-Degree Yield Function. Int. J. Mech. Sci.,1978,20:423-435
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62 赵军, 张双杰.圆锥形零件拉深成形过程中的接触应力分布的研究.机械工程学报,2000,7(2):51-54
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2 邵荷生.摩擦与磨损.北京:煤炭工业出版社,1992:1-87
3 李生智.金属压力加工概论.北京:冶金工业出版社,1984:1-27,148-155
4 白柯芬.金属压力加工学.北京:冶金工业出版社,1988:35-78
5 焦明山.金属压力加工中的摩擦和润滑手册.北京:航空工业出版社,1990:1-12,15-21
6 姚若浩.金属压力加工中的摩擦与润滑.北京:冶金工业出版社,1990:50-67
7 陆大雄.摩擦学.北京:北京出版社,1990:7-25
8 王松年.摩擦学原理及应用.北京:中国铁道出版社,1990:6-24
9 郑林庆.摩擦学原理.北京:高等教育出版社,1994:187-197
10 李晓焱.摩擦理论与摩擦系数:丹东纺专学报,1997,(3):34-36
11 林复生.简明摩擦学.重庆:重庆大学出版社,1987:1-10
12 Masami Konishi. Artificial Intelligence for Plastic Deformation.Journal of the Japan Society for Technology of Plasticity(JSTP),1993,(34): 345-351
13 Manabe,K. Artificial intelligence identification of process parameters and adaptive control system for deep-drawing process Journal of Materials Processing Technology,1998:421-426
14 Effects of process variables on V-die bending process of steel sheet International Journal of Mechanical Sciences,1998: 631-650
15 Chung Kwansoo,Ideal sheet forming with frictional constraints International Journal of Plasticity,2000: 595-610
16 Hassan,M.A. Friction aided deep drawing using newly developed blank-holder divided into eight segments International Journal of Machine Tools and Manufacture,2003: 637-646
17 Ken-ichi Manabe and M. Yang. Intelligent Technology on Sheet Metal Forming. Journal of the JSTP,1993,(34):398-404
18 H.J. Park et al.. A Fuzzy Self-Learning Control Method with Application to Hydroforming Processes. ASME Journal of Engineering for Industry,1995,117:197-303
Ken-ichi Kawai. Intelligent Spinning Technology. Journal of the JSTP,1993,
19 34(387):391-397
20 Lanzon,J.M. Characterising frictional behaviour in sheet metal forming Journal of Materials Processing Technology,1998:251-256
21 Kazuo Nose. Knowledge Engineering Applied to Automatic Flatness Control System for Aluminium Foil Rolling Mill. Journal of the JSTP,1993, 387 (34):358-362
22 H. B. Sim and M. C. Boyce. Finite Element Analysis of Real-time Stability Control in Sheet Forming Processes. ASME Journal of Engineering Materials and Technology,1992,114:181-188
23 全永昕.摩擦磨损原理.杭州:浙江大学出版社,1988:147-167
24 戴雄杰.摩擦学基础.上海:上海科学技术出版社,1984: 1-22
25 余俊.摩擦学.长沙:湖南科学技术出版社,1984:51-59
26 茹铮.塑性加工摩擦学.北京:科学出版社,1992:25-43,136-162
27 Smith,Bruce D. Financial Market Frictions,Monetary Policy,and Capital Accumulation in a Small Open Economy Journal of Economic Theory,1998: 353-400
28 Yamaguchi,K. Friction aided deep drawing of sheet metals using polyurethane ring and auxiliary metal punch. International Journal of Machine Tools and Manufacture,2002:633-642
29 Courvoisier. Analytical modelling of drawbeads in sheet metal forming Journal of Materials Processing Technology,American Society for Testing and Matesials,2003: 359-370
30 Murtagh,Adrian M. Surface friction effects related to pressforming of continuous fibre thermoplastic composites Composites Manufacturing,1995,169-175
31 Martinet,F.Application of ALE finite elements method to a lubricated friction model in sheet metal forming International Journal of Solids and Structures,2000,4005-4031
32 Leu,Daw-Kwei,Prediction of the maximum drawing load in the cup-drawing process of sheet metals Journal of Materials Processing Technology,1997,256-261
33 Hodgson,P.D. Effect of membrane stress on surface roughness changes in sheet forming,2002,610-617
34 Song Yuquan and Zhao Jun. A Mechanical Analysis of the Superplastic Free Bulging of Metal Sheet. Material SciencEngineering,1986,84:111-122
35 A. S. Wifi. An Incremental Complete Solution of the Stretch Forming and Deep Drawing of a Circular Blank Using a Hemispherical Punch. Int. J,1976,18:23-31
36 徐树成.板成形中摩擦系数测定的研究进展.塑性工程学报,1997,(2):39-44
37 徐树成.薄板深冲成形过程中摩擦系数的测定.塑性工程学报,2000,(4):25-28
38 孙英, 王先进, 康永林. 薄板冲压成形摩擦试验装置的开发及应用研究(硕士论文).北京:北京科技大学,1995:35-38
39 罗亚军.板材拉深成形智能化控制过程中摩擦系数的识别.锻压技术,2001,(2):38-42
40 汪锐.板材拉深成形过程中摩擦条件与压边力设定关系研究.锻压技术2001,(6):22-26
41 何丹农.拉深用润滑剂的摩擦系数和压边力的关系研究.摩擦学学报,2000,(3):34-37
42 赵军.圆锥形零件拉深成形智能化研究.[哈尔滨工业大学博士论文],1997:1,17-46
43 赵军, 曹宏强, 马丽霞等.锥形件智能化拉深实验系统.中国机械工程学会锻压学会第五届冲压学术年会论文集.南昌:江西高校出版社,1998:136-139
44 姜海峰, 赵军, 李硕本等.变压边力拉深的原理及实验系统.塑性工程学报,1999,6(1):30-33
45 赵军, 李硕本, 吕炎.板材冲压成形的智能化控制技术.塑性工程报,1999,6(4):10-21
46 王东哲.板料拉深成形摩擦测试系统研究.润滑与密封,2000,(5):35-39
47 张双杰, 马丽霞, 张金泉等. 圆锥形件拉深成形时悬空侧壁应力分布的实验研究,秦皇岛:燕山大学报,1999(23)140-142
48 王祖唐.金属塑性成形理论: 北京:机械工业出版社,1989:1
49 胡士光, 陈鹤峥.板料冷压成形原理(修订版).北京:国防工业出版社,1989:68-97
50 王川涛.金属成形的各种方法简介.金属成形工艺,1986,4(2):56-60
51 Ε.Π.翁克索夫, W.约翰逊, 工腾英明.金属塑性变形理论.王仲仁译:北京:机械工业出版社,1992:393-461
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