筒形件旋压成形有限元模拟及工艺分析
摘要
旋压成形可旋制无缝空心回转体零件,具有变形条件好、产品性能优、尺寸公差小、材料利用率高、产品类别广泛等优点,广泛应用于兵器、航空、航天、民用等金属精密加工技术领域。实际生产过程中影响产品质量的因素很多,各参数之间的合理搭配需要工艺人员在试生产中反复摸索调试。采用有限元数值模拟技术可以降低成本,提高生产效率,为工艺设计和实验研究提供指导。
本文以筒形件外旋压和带内筋筒形件内旋压过程为研究对象,基于MSC.Marc元平台,建立了旋压成形过程的三维有限元模型,并分析了其成形机理及工艺参数对成形过程的影响规律。
首先,根据有限元理论,毛坯采用六面体单元划分网格,对尾顶、芯模和旋轮进行了模型的离散化,并有效地解决了摩擦接触、边界约束与旋轮轨迹等关键问题。从而建立了合理的筒形件旋压成形有限元模型。
基于上述模型,得到筒形件外旋压变形过程中应力场、应变场分布规律。探讨了旋压方式和工艺参数对旋压力及工件质量的影响。针对TC4钛合金的正旋压工艺,研究结果显示：随着减薄率、进给比和圆角半径增加,各方向旋压力均呈增大趋势,径向旋压力增加速率较大；增大成形角,总旋压力和径向旋压力显著减小,而轴向旋压力呈增大趋势。
通过模拟,研究带内筋筒形件内旋压成形的基本规律及旋压力的变化趋势。分析了不同减薄率和进给比对金属流动、工件尺寸精度和内筋高度的影响。研究认为：随着减薄率增大,工件尺寸精度降低,内筋高度略有增大；当进给比在较小的范围(小于1.5mm/r)时,增大进给比,外径尺寸精度显著改善,而内筋高度明显减小。
Spinning easily manufactures the product of seamless hollow rotary body. It has many advantages, including good deformation conditions, excellent product performance, precise dimensional tolerance, high material utilization ratio, great product categories and so on. It has been widely applied in weapons, aviation, astronavigation, civil and other metal precision forming technology departments. In the process of manufacture, many process parameters affect the qualities of spinned parts, engineers have to establish process parameters by trial-and-error approach. Finite element numerical simulation technology may reduce cost, increase production efficiency and provide a guide for the process design and experimental study.
In this dissertation, outside spinning of tube and interior spinning of tube with inner rib are analyzed. Firstly,3D FEM models of these forming processes are established under MSC.Marc software environment, and then the deformation mechanism and the influencing laws of technological parameters are investigated.
First, by means of finite element theory, the hexahedron element has been used for plotting the blank. Clamp, mandrel and roller have been discreted respectively. Some key technologies have been solved, including friction condition, boundary condition and roller path etc. Then, reasonable FEM models of spinning of tube are established.
Based on the model established above, the distribution and variation features of the stress and strain during outside spinning of tube deformation have been obtained. The effects of spinning modes and technological parameters on spinning forces and workpiece quality have been analyzed. The results demonstrate that spinning forces increase with the increasing of reduction, feed rate and fillet radius, especially the radial spinning force. With the increasing of the forming angle, the total spinning force and radial spinning force decrease rapidly, but the axial spinning force increases slightly.
Deformation law and variation tendency of spinning force have been researched during interior spinning of tube with rib by simulation. The influence of reduction and feed rate on metal flow, dimensional precision and height of the inner rib are studied. Researches show that with the increasing of reduction, dimensional precision decreases and the height of the inner rib enhances a little. With the increasing of feed rate, dimensional precision significantly improves, but the height of the inner rib reduces rapidly when feed rate is under 1.5 mm/r.
本文以筒形件外旋压和带内筋筒形件内旋压过程为研究对象,基于MSC.Marc元平台,建立了旋压成形过程的三维有限元模型,并分析了其成形机理及工艺参数对成形过程的影响规律。
首先,根据有限元理论,毛坯采用六面体单元划分网格,对尾顶、芯模和旋轮进行了模型的离散化,并有效地解决了摩擦接触、边界约束与旋轮轨迹等关键问题。从而建立了合理的筒形件旋压成形有限元模型。
基于上述模型,得到筒形件外旋压变形过程中应力场、应变场分布规律。探讨了旋压方式和工艺参数对旋压力及工件质量的影响。针对TC4钛合金的正旋压工艺,研究结果显示：随着减薄率、进给比和圆角半径增加,各方向旋压力均呈增大趋势,径向旋压力增加速率较大；增大成形角,总旋压力和径向旋压力显著减小,而轴向旋压力呈增大趋势。
通过模拟,研究带内筋筒形件内旋压成形的基本规律及旋压力的变化趋势。分析了不同减薄率和进给比对金属流动、工件尺寸精度和内筋高度的影响。研究认为：随着减薄率增大,工件尺寸精度降低,内筋高度略有增大；当进给比在较小的范围(小于1.5mm/r)时,增大进给比,外径尺寸精度显著改善,而内筋高度明显减小。
Spinning easily manufactures the product of seamless hollow rotary body. It has many advantages, including good deformation conditions, excellent product performance, precise dimensional tolerance, high material utilization ratio, great product categories and so on. It has been widely applied in weapons, aviation, astronavigation, civil and other metal precision forming technology departments. In the process of manufacture, many process parameters affect the qualities of spinned parts, engineers have to establish process parameters by trial-and-error approach. Finite element numerical simulation technology may reduce cost, increase production efficiency and provide a guide for the process design and experimental study.
In this dissertation, outside spinning of tube and interior spinning of tube with inner rib are analyzed. Firstly,3D FEM models of these forming processes are established under MSC.Marc software environment, and then the deformation mechanism and the influencing laws of technological parameters are investigated.
First, by means of finite element theory, the hexahedron element has been used for plotting the blank. Clamp, mandrel and roller have been discreted respectively. Some key technologies have been solved, including friction condition, boundary condition and roller path etc. Then, reasonable FEM models of spinning of tube are established.
Based on the model established above, the distribution and variation features of the stress and strain during outside spinning of tube deformation have been obtained. The effects of spinning modes and technological parameters on spinning forces and workpiece quality have been analyzed. The results demonstrate that spinning forces increase with the increasing of reduction, feed rate and fillet radius, especially the radial spinning force. With the increasing of the forming angle, the total spinning force and radial spinning force decrease rapidly, but the axial spinning force increases slightly.
Deformation law and variation tendency of spinning force have been researched during interior spinning of tube with rib by simulation. The influence of reduction and feed rate on metal flow, dimensional precision and height of the inner rib are studied. Researches show that with the increasing of reduction, dimensional precision decreases and the height of the inner rib enhances a little. With the increasing of feed rate, dimensional precision significantly improves, but the height of the inner rib reduces rapidly when feed rate is under 1.5 mm/r.
引文
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[5]王浩然.模环旋压成形过程的数值模拟与工艺优化[D].大连：大连理工大学,2008.
[6]周强.突变壁厚锥形件强力旋压成形有限元模拟与试验研究[D].西安：西北工业大学,2007.
[7]张利鹏,刘智冲,周宏宇.带内筋筒形件强力旋压成形试验研究[J]CMET.锻压装备与制造技术,2005(4)：86-88.
[8]张利鹏,刘智冲.带内筋铝合金筒形件强力旋压成形工艺研究[J].塑性工程学报,2007,14(6)：109-113.
[9]薛克敏,江树勇,康达昌.带纵向内筋薄壁筒形件强旋成形[J].材料科学与工艺,2002,10(3)：287-290.
[10]许春停,薛克敏,李萍.带纵向内筋筒形件滚珠反旋工艺模拟和缺陷分析[J].河南科技大学学报：自然科学版,2006,27(4)：9-11.
[11]江树勇,顾卫东,李春峰等.纵向内筋薄壁筒反向滚珠旋压成形机理研究[J].锻压技术,2008,33(5)：88-91.
[12]S. Y. Jiang, Y. F. Zhang, Z. Y. Ren. Multi-pass spinning of thin-walled tubular part with longitudinal inner ribs[J]. Transactions of nonferrous metals society of china, 2009(19):215-221
[13]夏琴香,李小曼,李小龙等.梯形内齿旋压成形过程数值模拟及试验研究[J].锻压技术,2008,33(6)：57-62.
[14]周强,詹梅,杨合.带横向内筋锥形件旋压应力应变场的有限元分析[J].塑性工程学报,2007,14(3)：49-53.
[15]Q. Bai, H. Yang, M. Zhan. Finite element modeling of power spinning of thin-walled shell with hoop inner rib[J]. Transactions of nonferrous metals society of china,2008, (18):6-13.
[16]肖景容,李尚健.塑性成形模拟理论[M].武昌：华中理工大学出版社,1994：77-94.
[17]徐银丽.异型薄壁壳体强力旋压成形机理及规律的三维有限元分析[D].西安：西北工业大学,2006.
[18]周昌玉,贺小华.有限元分析的基本方法及工程应用[M].北京：化学工业出版社,2006.
[19]李超玲.筒形件强力旋压过程的有限元数值模拟[D].西安：西北工业大学,2004.
[20]刘粉妮.筒形变薄旋压加工有限元分析[D].成都：四川大学,2006.
[21]杜坤.筒形件多道次普通缩旋三维弹塑性有限元模拟[D].西安：西北工业大学,2001.
[22]陈如欣,胡忠民.塑性有限元法及其在金属成形中的应用[M].重庆大学出版社,1988.
[23]韩志仁,陶华等.筒形件强力内旋压有限元模拟[J].机械科学与技术,2004,23(1)：63-65.
[24]谢世坤,赵孝养,程从山等.板料成形有限元分析的发展综述[J].井冈山学院学报,2006,27(4)：48-52.
[25]陈火红,于军泉,席泉山.MSC. Marc/Mentat基础与应用实例[M].北京：科学出版社,2004.
[26]张利鹏,刘智冲.筒形件强力旋压工艺参数选取方式分析[J].锻压技术.2006,(11)：44.
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