变值成形原理与设备设计理论的若干关键问题研究
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摘要
变值成形是通过改变金属材料截面的尺寸和形状,直接制造零件或毛坯的工艺方法,是机械制造技术与轧制技术交叉复合而成的零件制造方法,具有改善工件材料组织性能、节省材料、生产率高的特点,是21世纪大力发展的技术。本文对其成形原理与设备设计理论中的若干关键问题进行了理论和实验研究。
提出了变值轧制成形的概念。探讨了变值轧制成形的基本现象和规律,初步建立了变值轧制成形的基本理论框架。分析了咬入条件、咬入角、接触角、咬入条件与接触角的关系和变值轧制成形状态下金属运动形式及速度规律,推导了变形速率的计算公式;研究了压下量对咬入角、接触角、变形区长度的影响规律,建立了轧透性判定模型和最小压下量公式。
研究了金属变形区的滑动规律。分析了接触角随工件厚度曲线变化规律和对变形区金属滑动规律的影响作用;建立了变值轧制条件下前滑、后滑、断面变化系数等参数的数学模型;分析了变值成形条件下变形区表面摩擦状态和机理,利用预位移理论解释了中性面处的摩擦机理;讨论了影响摩擦和滑动的因素。
建立了基于上限定理的设备载荷力能参数计算方法。通过建立变形区边界方程
Variable-data forming (VDF), manufacturing works or rough parts directly by changing the material cross-section size and shape, is a technology and method which is crossed by machine building with rolling. The technology, having the features of improving material properties and saving material and high productivity, etc, is a promising process in the 21th century. Some key questions in the forming principle and equipment design theory has been studied in the paper.The concept of VDA has been put out and the basic phenomenon and law of that have been researched and the theorical system of that has been set up. The biting condition and the relationship of contact angle with biting angle and with bite condition have been built. The metal moving form, speed law, deforming rate formula in variable-data farming have been studied. The affecting law of draught on biting angle and contact angle and the length of deforming zone have been studied. The judgment condition of rolling penetration and the formula of least reduction in pass have been built.The slip law of metal in the deforming zone and the change law of contacting angle with the works thickness curve slope and the effect of that on the metal in the deforming zone have been studied. The formula of forward slip and backward slip and section change coefficient has been built. The friction state and principle in the deforming zone of variable-data farming have been analyzed. With the theory of forecast displacement, the friction principle on neutral flow plane has been studied. The factor affecting friction and slip has been discussedBased on Upper-bound theorem, the calculating method of dynamics
parameter of load on equipment has been found. By building deformation zone boundary function and cross-section speed function, the allowable velocity field and strain rate field of deformation zone bave been studied. The calculation method of plastic deformation power in deformation zone and shear power on the speed discontinuous surface and friction power on the friction surface bave been studied. The Upper-bound power calculation formula, satisfying Mises yield condition and Levy-Mises flow rule, has been put forward. The formula of forming force and moment has been obtained finaly. The accuracy of forming force calculation formula is proved by test.The basic law of metal spread has been studied. The form and cause of that have been analyzed. Under the spread branch zone hypothesis and based on the condition of minimum flow resistance and volume constant, the spread formula, which is satifying application by comparing test data with model data, has been put forward,.The concept of V-H one-pass rolling, by which the three-dimensional deformation is turn to double two-dimensional deformation to control and form, has been put out. The technology and theory and math-model and the phenomena such as works shape and forming stability of V-H one-pass rolling have been studied. The shape simulation to test V-H forming theory has been completed. The V-H forming theory has been set up.The mapping relationship of concurrent step design and the judging rule composed by functionality and information and circulation have been put out. The mechanism shape of V-H forming equipment has been studied. The concept of stress-loops has been put forward and used to improve equipment rigidity. The power type and control shape and math formula have been studied. The accuracy and practicality of stress-loops improving equipment rigidity have been checked by the finite element method. The shape and size of rolls could be obtained. The feasibility and accuracy of technologic method of V-H forming are shown by test. The key equipment of V-H forming has been developed.
提出了变值轧制成形的概念。探讨了变值轧制成形的基本现象和规律,初步建立了变值轧制成形的基本理论框架。分析了咬入条件、咬入角、接触角、咬入条件与接触角的关系和变值轧制成形状态下金属运动形式及速度规律,推导了变形速率的计算公式;研究了压下量对咬入角、接触角、变形区长度的影响规律,建立了轧透性判定模型和最小压下量公式。
研究了金属变形区的滑动规律。分析了接触角随工件厚度曲线变化规律和对变形区金属滑动规律的影响作用;建立了变值轧制条件下前滑、后滑、断面变化系数等参数的数学模型;分析了变值成形条件下变形区表面摩擦状态和机理,利用预位移理论解释了中性面处的摩擦机理;讨论了影响摩擦和滑动的因素。
建立了基于上限定理的设备载荷力能参数计算方法。通过建立变形区边界方程
Variable-data forming (VDF), manufacturing works or rough parts directly by changing the material cross-section size and shape, is a technology and method which is crossed by machine building with rolling. The technology, having the features of improving material properties and saving material and high productivity, etc, is a promising process in the 21th century. Some key questions in the forming principle and equipment design theory has been studied in the paper.The concept of VDA has been put out and the basic phenomenon and law of that have been researched and the theorical system of that has been set up. The biting condition and the relationship of contact angle with biting angle and with bite condition have been built. The metal moving form, speed law, deforming rate formula in variable-data farming have been studied. The affecting law of draught on biting angle and contact angle and the length of deforming zone have been studied. The judgment condition of rolling penetration and the formula of least reduction in pass have been built.The slip law of metal in the deforming zone and the change law of contacting angle with the works thickness curve slope and the effect of that on the metal in the deforming zone have been studied. The formula of forward slip and backward slip and section change coefficient has been built. The friction state and principle in the deforming zone of variable-data farming have been analyzed. With the theory of forecast displacement, the friction principle on neutral flow plane has been studied. The factor affecting friction and slip has been discussedBased on Upper-bound theorem, the calculating method of dynamics
parameter of load on equipment has been found. By building deformation zone boundary function and cross-section speed function, the allowable velocity field and strain rate field of deformation zone bave been studied. The calculation method of plastic deformation power in deformation zone and shear power on the speed discontinuous surface and friction power on the friction surface bave been studied. The Upper-bound power calculation formula, satisfying Mises yield condition and Levy-Mises flow rule, has been put forward. The formula of forming force and moment has been obtained finaly. The accuracy of forming force calculation formula is proved by test.The basic law of metal spread has been studied. The form and cause of that have been analyzed. Under the spread branch zone hypothesis and based on the condition of minimum flow resistance and volume constant, the spread formula, which is satifying application by comparing test data with model data, has been put forward,.The concept of V-H one-pass rolling, by which the three-dimensional deformation is turn to double two-dimensional deformation to control and form, has been put out. The technology and theory and math-model and the phenomena such as works shape and forming stability of V-H one-pass rolling have been studied. The shape simulation to test V-H forming theory has been completed. The V-H forming theory has been set up.The mapping relationship of concurrent step design and the judging rule composed by functionality and information and circulation have been put out. The mechanism shape of V-H forming equipment has been studied. The concept of stress-loops has been put forward and used to improve equipment rigidity. The power type and control shape and math formula have been studied. The accuracy and practicality of stress-loops improving equipment rigidity have been checked by the finite element method. The shape and size of rolls could be obtained. The feasibility and accuracy of technologic method of V-H forming are shown by test. The key equipment of V-H forming has been developed.
引文
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