钛合金高压容器成形过程的有限元模拟
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摘要
随着航空、航天工业的发展与技术进步，钛及钛合金在国防工业中的应用越来越广泛。作为航空、航天难变形材料，钛合金以其变形抗力大、工艺参数容差小、成形件质量对工艺参数敏感且难以控制等特点而成形困难。采用传统的工艺设计与控制方法，很难快捷而有效地生产出合格的零件。这亟待从工艺过程设计、质量控制体系和生产过程控制等方面入手来提高航空、航天难变形的工艺设计水平与成形制造精度。
本文以航天用某型号高压容器为研究对象，针对其所用材料TC4合金的成形特点，采用有限元数值模拟软件，分析研究了不同工艺条件下TC4合金的成形规律，并以此为基础，对某牌号高压容器各组成部分的实际成形过程进行了数值模拟与仿真。主要成果和新见解如下：
1．通过工艺分析和材料变形特点的研究，将所研究的高压容器分解为左、中、右三段，并分别采用不同的工艺过程进行成形。通过分析认为：左封头零件适用于精密热模锻工艺；中间筒形件适用于强力旋压工艺；右封头球形件适用于拉延成形工艺。
2．采用刚(粘)塑性热力耦合有限元数值模拟方法，分析研究了TC4合金高压容器左封头的锻造成形过程，重点研究了在热模锻过程中成形件组织与工艺参数间的耦合分析问题，给出了TC4合金锻造过程中的载荷行程曲线及再结晶组织分布情况，并分析研究了主要工艺参数对左封头成形过程的影响规律。
3．采用三维弹塑性有限元数值模拟方法，分析研究了TC4合金高压容器中间段筒形件的强力旋压过程，在分析钛合金材料强力旋压特点的基础上，初步确立了TC4合金强旋过程的工艺参数，研究了冷、热旋压工艺对TC4合金强力旋压过程的影响，获得了温度场对强力旋压工艺的影响规律以及旋轮作用区及其相邻区域的场变量分布情况。
4．采用大变形弹塑性有限元数值模拟方法，分析研究了TC4合金高压容器右封头球形件的拉延成形过程，在对成形板料进行分区讨论的基础上，重点给出了钛合金球形件在拉延成形过程中的回弹规律，并就凸模压下速度对拉延成形过程的影响进行了研究。
With the development of aviation and astronavigation industry and the advancement of technology, the use of titanium and titanium alloy in national defence become wider and wider. Titanium alloy, as the materials difficult to deformation of aviation and astronavigation, has some characters hard to deformation, such as giant resistance of deformation, small processing parameter allowance and quality of formed parts sensitive to processing parameter and hard to control. It is difficult to produce qualified parts with high efficiency by existing facilities and traditional technologies of process design and control to satisfy production demand of modern national defence. It is urgent to be started with development of technological design, quality control system and product control in order to improve the design level of technology hard to deformation and the manufacturing accuracy.
Taking the deformation of the high pressure vessel used in astronavigation as subject investigated, based on deformation characters of Ti-6Al-4V alloy, the properties of deformation of Ti-6Al-4V alloy have been analyzed by FEM numerical simulation in different technological conditions. On this basis, actual deformation processes of different parts of high pressure vessel are analyzed by numerical simulation. The main research findings and new outlooks are as follows:
(1) According to research the process and forming characters of material, high pressure vessel researched is separated into three sections of the left, the middle and the right. These three sections are formed by different deforming process. Based on the thorough analysis and study, the left head is proper to precision thermal die forging, the middle cylindrical workpiece to power spinning and the right head to drawing.
(2) The forging process of the left head of high pressure vessel of TU6A1-4V alloy is analyzed with rigid-visco-plastic thermodynamic coupled FEM numerical simulation. The coupling problem between microstructure of forgings and processing parameters in thermal die forging is studied. The load-distance curve and distribution
of the recrystal microstructxxre in forging process of TJ-6A1-4V alloy are obtaiaed, and the influence of major processing parameters on deforming process is analyzed.
(3) The power spinning of the middle cylindrical workpiece of high pressure vessel of Ti-6Al-4V alloy is analyzed with three-dimensional elastic-plastic FEM numerical simulation. On the basis of study of characters of power spinning of titanium alloy, processing parameters of power spinning of Ti-6Al-4V alloy are determined. The influence of cool spinning and thermal spinning on power spinning process of T1-6A1-4V alloy is studied. The influence of temperature on power spinning process and the distribution of field variable around roller are obtained, and power spinning process of the cylindrical workpiece with rib is analyzed.
(4) The drawing process of the right head of high pressure vessel of Ti-6Al-4V alloy is analyzed with elastic-plastic FEM numerical simulation. On the basis of discussion of deformation of sheet, the spring-back of drawing deformation of ball workpiece of T1-6A1-4V alloy and the influence of velocity of punch on drawing process are studied.
本文以航天用某型号高压容器为研究对象，针对其所用材料TC4合金的成形特点，采用有限元数值模拟软件，分析研究了不同工艺条件下TC4合金的成形规律，并以此为基础，对某牌号高压容器各组成部分的实际成形过程进行了数值模拟与仿真。主要成果和新见解如下：
1．通过工艺分析和材料变形特点的研究，将所研究的高压容器分解为左、中、右三段，并分别采用不同的工艺过程进行成形。通过分析认为：左封头零件适用于精密热模锻工艺；中间筒形件适用于强力旋压工艺；右封头球形件适用于拉延成形工艺。
2．采用刚(粘)塑性热力耦合有限元数值模拟方法，分析研究了TC4合金高压容器左封头的锻造成形过程，重点研究了在热模锻过程中成形件组织与工艺参数间的耦合分析问题，给出了TC4合金锻造过程中的载荷行程曲线及再结晶组织分布情况，并分析研究了主要工艺参数对左封头成形过程的影响规律。
3．采用三维弹塑性有限元数值模拟方法，分析研究了TC4合金高压容器中间段筒形件的强力旋压过程，在分析钛合金材料强力旋压特点的基础上，初步确立了TC4合金强旋过程的工艺参数，研究了冷、热旋压工艺对TC4合金强力旋压过程的影响，获得了温度场对强力旋压工艺的影响规律以及旋轮作用区及其相邻区域的场变量分布情况。
4．采用大变形弹塑性有限元数值模拟方法，分析研究了TC4合金高压容器右封头球形件的拉延成形过程，在对成形板料进行分区讨论的基础上，重点给出了钛合金球形件在拉延成形过程中的回弹规律，并就凸模压下速度对拉延成形过程的影响进行了研究。
With the development of aviation and astronavigation industry and the advancement of technology, the use of titanium and titanium alloy in national defence become wider and wider. Titanium alloy, as the materials difficult to deformation of aviation and astronavigation, has some characters hard to deformation, such as giant resistance of deformation, small processing parameter allowance and quality of formed parts sensitive to processing parameter and hard to control. It is difficult to produce qualified parts with high efficiency by existing facilities and traditional technologies of process design and control to satisfy production demand of modern national defence. It is urgent to be started with development of technological design, quality control system and product control in order to improve the design level of technology hard to deformation and the manufacturing accuracy.
Taking the deformation of the high pressure vessel used in astronavigation as subject investigated, based on deformation characters of Ti-6Al-4V alloy, the properties of deformation of Ti-6Al-4V alloy have been analyzed by FEM numerical simulation in different technological conditions. On this basis, actual deformation processes of different parts of high pressure vessel are analyzed by numerical simulation. The main research findings and new outlooks are as follows:
(1) According to research the process and forming characters of material, high pressure vessel researched is separated into three sections of the left, the middle and the right. These three sections are formed by different deforming process. Based on the thorough analysis and study, the left head is proper to precision thermal die forging, the middle cylindrical workpiece to power spinning and the right head to drawing.
(2) The forging process of the left head of high pressure vessel of TU6A1-4V alloy is analyzed with rigid-visco-plastic thermodynamic coupled FEM numerical simulation. The coupling problem between microstructure of forgings and processing parameters in thermal die forging is studied. The load-distance curve and distribution
of the recrystal microstructxxre in forging process of TJ-6A1-4V alloy are obtaiaed, and the influence of major processing parameters on deforming process is analyzed.
(3) The power spinning of the middle cylindrical workpiece of high pressure vessel of Ti-6Al-4V alloy is analyzed with three-dimensional elastic-plastic FEM numerical simulation. On the basis of study of characters of power spinning of titanium alloy, processing parameters of power spinning of Ti-6Al-4V alloy are determined. The influence of cool spinning and thermal spinning on power spinning process of T1-6A1-4V alloy is studied. The influence of temperature on power spinning process and the distribution of field variable around roller are obtained, and power spinning process of the cylindrical workpiece with rib is analyzed.
(4) The drawing process of the right head of high pressure vessel of Ti-6Al-4V alloy is analyzed with elastic-plastic FEM numerical simulation. On the basis of discussion of deformation of sheet, the spring-back of drawing deformation of ball workpiece of T1-6A1-4V alloy and the influence of velocity of punch on drawing process are studied.
引文
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[14] R.Prakash,R.P.Singhal. Shear Spinning Technology for Manufacture of Long Thin Wall Tubes of Small Bore. J.Mater. Process. Technol.,1995,54(1-4):186-192
[15] M.I.Rotarescu. A Theoretical Analysis of Tube Spinning Using Balls. J.Mater. Process.Technol.,1995,54:224-229
[16] 李玉强．多道次拉深旋压成形规律的研究．西北工业大学硕士学位论文，2000年3月
[17] M.M.EL-Khabeery, M.Fattouh,M.N.E-Sheikh. On the Conventional Simple Spinning of Cylindrical Aluminum Cups. International Journal of Machine Tools & Manufacture, 1991 (2):203-219
[18] R.P. Singhal,P.K.Saxena,R.Prakash. Estimation of Power in the Shear Spinning of Long Tubes in Hard-to-work Materials. J.Mater. Process. Technol., 1990(23):
29-40
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