微塑性成形机理及精密微塑性体积成形装置研究
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摘要
微机电系统和微系统技术的迅速发展,对微型零件的制造技术提出了更高要求,这给精密微塑性成形技术的发展带来契机。该成形技术是以塑性变形方式制造微型零件的工艺方法,非常适合于微型零件的低成本批量制造,但由于成形件尺寸或特征尺寸为亚毫米级或微米量级,出现了明显的尺寸效应,与传统的塑性加工工艺不同,其成形机理和材料变形流动规律发生了改变,微塑性成形技术是一个崭新的研究领域。
本文建立了基于晶体塑性学理论的多晶体模型,揭示了材料微塑性成形机理,使用压电陶瓷微驱动器研制了精密微塑性体积成形专用设备,开展了微塑性成形尺寸效应的实验研究,并以微型齿轮作为典型零件系统地研究了微型零件的微塑性成形工艺,解决了制约微塑性成形工艺的关键技术。
从材料的多晶体结构角度,基于晶体塑性变形理论建立了多晶体模型。根据位错塞积程度和晶粒变形受约束程度的差异将变形体分作两部分:位于自由表面的单晶体区和变形体内部的多晶体区。位于变形体自由表面的晶粒变形采用晶体塑性学理论来分析,而内部材料采用宏观塑性变形理论分析。使用建立的多晶体模型对微型圆柱试样的镦粗变形过程进行了数值分析,研究了试样尺寸、晶粒初始取向分布等对试样流动应力和表面形貌的影响规律。结果表明,试样的流动应力随试样尺寸的减小而减小,出现了明显的尺寸效应现象;试样的变形不均匀性是由试样晶粒的各向异性引起的,导致了变形试样表面凹凸不平。
采用压电陶瓷作为微驱动器,研制了串联式结构的精密微塑性体积成形装置。设计了位置调节机构用于压电陶瓷位置调节,同时还可以满足某些成形工艺中对较大位移量的需要。使用基于PID控制的压电陶瓷电源,针对微塑性成形设计了成形工艺控制器。对研制的精密微塑性体积成形装置进行了测试和分析,结果表明该装置能够满足微塑性体积成形研究的需要。
使用微镦粗实验方法进行实验研究,分析试样尺寸、晶粒尺寸、变形程度和变形温度等参数对材料流动应力的影响规律,并从材料的多晶体结构角度对流动应力尺寸效应产生的机理进行了分析。采用金相方法,分析晶粒尺寸和变形程度对塑性变形不均匀性的影响规律,并从晶粒的各向异性角度研究其产生的机理。
模具型腔的尺度也会对微成形工艺带来尺寸效应。本文采用模压成形工艺,研究了模具型腔尺寸(b)、晶粒尺寸(L)以及它们的比值L/b对充填性能的影响规律。结果表明,比值L/b是影响材料微充填性能的主要因素。
在以上研究的基础上,开展了微型齿轮的微塑性成形工艺研究。使用研制的浮动式模具装置,研究了微型齿轮的微塑性成形过程,分析了冲头速度、载荷和温度等工艺参数对微塑性成形工艺的影响规律,并从坯料的受力状态以及材料的多晶体结构角度对坯料的充填规律进行了分析。研究了微型齿轮纵截面和横截面的流线分布规律,并对齿轮的表面粗糙度和横截面上的纳米硬度进行测量。结果表明,成形的微型齿轮有良好的表面质量和综合性能。
With the rapid development of micro-electro-mechanical systems and micro-system technology, a high requirement is taken out for the micropart manufacture technology, which gives a chance of development for the microforming technology. The technology is a process to manufacture micropart by plastic deformation, and it is very suitable for the low-cost and mass production of micropart. Since part dimension or typical dimension reaches the same order of magnitude as sub-millimeter or micron, and the size effect occurs obviously, microforming process is different from the traditional plastic deformation. And the forming mechanism and deformation law change, then micrforming process becomes a new research area.
This dissertation founds a polycrystal model based on crystal plasticity, and the microforming mechanism is disclosed. Using the developed special precision microforming apparatus that is drove by a PZT, the experimental investigation of size effect in microforming process is carried out, and the forming process of micropart is studied by using the typical microgear as the forming object. The key technology that constrains microforming process is settled.
From the viewpoint of multi-grain structure of material, a polycrystal model is founded based on the crystal plasticity theory. A deformable body is divided into two parts based on the difference of the dislocation pile-up degree and deformation restriction of grain, and they are single crystal area on the free surface and polycrystal area in the internal portion of deformable body. The areas are analyzed by the crystal plasticity and traditional plastic deformaton theory respectively. The upsetting deformation of micro cylindrical specimen is simulated by the founded model, and the effect of specimen size and grain original direction on the flow stress and surface topography is investigated. The result shows that the flow stress decreases with the decreasing of the specimen size, the size effect occurs obviously. And the deformation ununiformity is caused by the anisotropy of the grain, which leads to irregularity surface of deformed specimen.
To carry out experimental investigation of microforming process, a precision micro bulk forming apparatus is developed with a series-wound structure using a PZT as the punch driver. A position adjustment device is designed to adjust the position of the PZT, and it can also meet the requirement of the large displacement in some processes. A PZT driver based on a PID control method is selected, and a process controller is designed for the microforming process. The test and analysis of the micro bulk forming apparatus show that it is suitable for the experimental research of the microforming process.
The experimental investigation is carried out by the upsetting test. The effect of specimen size, grain size, deformation degree and temperature on the flow stress is studied, and the mechanism of size effects is analyzed from the viewpoint of polycrystal structure. Using the metallography, the effect of grain size and strain on deformation ununiformity are investigated, and the mechanism is analyzed from the viewpoint of the anisotropy of grain.
The cavity dimension also leads to size effect in microforming process. A coining process is used in the dissertation, and the effect of the die cavity dimension (b), grain size (L) and their ratio L/b on the filling ability are investigated. The result shows that ratio L/b is the main effect factor.
Based on the above research, the investigation of microforming process of typical microgear is carried out. Using the developed floating die device, the forming procedure of micogear is studied. Effect of punch speed, load and forming temperature on the microforming process is studied, and the filling law is analyzed from the viewpoint of stress station and polycrystal structure of the specimen. The distribution of flow lines in the longitudinal section and the cross section is analyzed, and the measurement of surface roughness and nano-hardness in cross section of the microgear is implemented. The results show that the formed microgear owns fine surface quality and compositive capability.
本文建立了基于晶体塑性学理论的多晶体模型,揭示了材料微塑性成形机理,使用压电陶瓷微驱动器研制了精密微塑性体积成形专用设备,开展了微塑性成形尺寸效应的实验研究,并以微型齿轮作为典型零件系统地研究了微型零件的微塑性成形工艺,解决了制约微塑性成形工艺的关键技术。
从材料的多晶体结构角度,基于晶体塑性变形理论建立了多晶体模型。根据位错塞积程度和晶粒变形受约束程度的差异将变形体分作两部分:位于自由表面的单晶体区和变形体内部的多晶体区。位于变形体自由表面的晶粒变形采用晶体塑性学理论来分析,而内部材料采用宏观塑性变形理论分析。使用建立的多晶体模型对微型圆柱试样的镦粗变形过程进行了数值分析,研究了试样尺寸、晶粒初始取向分布等对试样流动应力和表面形貌的影响规律。结果表明,试样的流动应力随试样尺寸的减小而减小,出现了明显的尺寸效应现象;试样的变形不均匀性是由试样晶粒的各向异性引起的,导致了变形试样表面凹凸不平。
采用压电陶瓷作为微驱动器,研制了串联式结构的精密微塑性体积成形装置。设计了位置调节机构用于压电陶瓷位置调节,同时还可以满足某些成形工艺中对较大位移量的需要。使用基于PID控制的压电陶瓷电源,针对微塑性成形设计了成形工艺控制器。对研制的精密微塑性体积成形装置进行了测试和分析,结果表明该装置能够满足微塑性体积成形研究的需要。
使用微镦粗实验方法进行实验研究,分析试样尺寸、晶粒尺寸、变形程度和变形温度等参数对材料流动应力的影响规律,并从材料的多晶体结构角度对流动应力尺寸效应产生的机理进行了分析。采用金相方法,分析晶粒尺寸和变形程度对塑性变形不均匀性的影响规律,并从晶粒的各向异性角度研究其产生的机理。
模具型腔的尺度也会对微成形工艺带来尺寸效应。本文采用模压成形工艺,研究了模具型腔尺寸(b)、晶粒尺寸(L)以及它们的比值L/b对充填性能的影响规律。结果表明,比值L/b是影响材料微充填性能的主要因素。
在以上研究的基础上,开展了微型齿轮的微塑性成形工艺研究。使用研制的浮动式模具装置,研究了微型齿轮的微塑性成形过程,分析了冲头速度、载荷和温度等工艺参数对微塑性成形工艺的影响规律,并从坯料的受力状态以及材料的多晶体结构角度对坯料的充填规律进行了分析。研究了微型齿轮纵截面和横截面的流线分布规律,并对齿轮的表面粗糙度和横截面上的纳米硬度进行测量。结果表明,成形的微型齿轮有良好的表面质量和综合性能。
With the rapid development of micro-electro-mechanical systems and micro-system technology, a high requirement is taken out for the micropart manufacture technology, which gives a chance of development for the microforming technology. The technology is a process to manufacture micropart by plastic deformation, and it is very suitable for the low-cost and mass production of micropart. Since part dimension or typical dimension reaches the same order of magnitude as sub-millimeter or micron, and the size effect occurs obviously, microforming process is different from the traditional plastic deformation. And the forming mechanism and deformation law change, then micrforming process becomes a new research area.
This dissertation founds a polycrystal model based on crystal plasticity, and the microforming mechanism is disclosed. Using the developed special precision microforming apparatus that is drove by a PZT, the experimental investigation of size effect in microforming process is carried out, and the forming process of micropart is studied by using the typical microgear as the forming object. The key technology that constrains microforming process is settled.
From the viewpoint of multi-grain structure of material, a polycrystal model is founded based on the crystal plasticity theory. A deformable body is divided into two parts based on the difference of the dislocation pile-up degree and deformation restriction of grain, and they are single crystal area on the free surface and polycrystal area in the internal portion of deformable body. The areas are analyzed by the crystal plasticity and traditional plastic deformaton theory respectively. The upsetting deformation of micro cylindrical specimen is simulated by the founded model, and the effect of specimen size and grain original direction on the flow stress and surface topography is investigated. The result shows that the flow stress decreases with the decreasing of the specimen size, the size effect occurs obviously. And the deformation ununiformity is caused by the anisotropy of the grain, which leads to irregularity surface of deformed specimen.
To carry out experimental investigation of microforming process, a precision micro bulk forming apparatus is developed with a series-wound structure using a PZT as the punch driver. A position adjustment device is designed to adjust the position of the PZT, and it can also meet the requirement of the large displacement in some processes. A PZT driver based on a PID control method is selected, and a process controller is designed for the microforming process. The test and analysis of the micro bulk forming apparatus show that it is suitable for the experimental research of the microforming process.
The experimental investigation is carried out by the upsetting test. The effect of specimen size, grain size, deformation degree and temperature on the flow stress is studied, and the mechanism of size effects is analyzed from the viewpoint of polycrystal structure. Using the metallography, the effect of grain size and strain on deformation ununiformity are investigated, and the mechanism is analyzed from the viewpoint of the anisotropy of grain.
The cavity dimension also leads to size effect in microforming process. A coining process is used in the dissertation, and the effect of the die cavity dimension (b), grain size (L) and their ratio L/b on the filling ability are investigated. The result shows that ratio L/b is the main effect factor.
Based on the above research, the investigation of microforming process of typical microgear is carried out. Using the developed floating die device, the forming procedure of micogear is studied. Effect of punch speed, load and forming temperature on the microforming process is studied, and the filling law is analyzed from the viewpoint of stress station and polycrystal structure of the specimen. The distribution of flow lines in the longitudinal section and the cross section is analyzed, and the measurement of surface roughness and nano-hardness in cross section of the microgear is implemented. The results show that the formed microgear owns fine surface quality and compositive capability.
引文
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