管材无凹模冲孔数值模拟与实验研究

利用DEFORM-3D软件对管材无凹模冲孔进行了一系列有限元模拟,根据模拟得到的数据建立了数学模型,定量分析了管材无凹模冲孔时凹坑变形量的大小与钢管的直径、孔的大小、壁厚、材质和模具设计等工艺设计参数之间的关系,再根据实验测量值,修正了模拟偏差,得到了无凹模冲孔凹坑变形量与成形参数之间的数学公式.     

扁袋笼顶盖冲压模设计与成形分析

在扁袋笼顶盖零件工艺分析的基础上,得出其优化工艺为落料—浅拉深（小于内壁高）—冲孔—内翻边,重点介绍落料拉深复合模的设计和三维建模。为了保证扁袋笼顶盖拉深成功,采用Dynaform软件模拟了扁袋笼顶盖的成形过程,对凸模圆角、凹模圆角和压边力工艺参数进行优化,并得到了其成形极限和减薄量图。结果显示,当凸模圆角5 mm、凹模圆角6.5 mm、压边力为50 kN时成形效果较好,无明显缺陷。     

冲裁模刃口尺寸计算公式

在冲裁模设计中,冲裁模的凸模、凹模刃口尺寸计算公式是根据落料以凹模为基准件配制凸模,冲孔以凸模为基准件配制凹模的原则建立的。但在实际生产中,由于条件和习惯的原因,部分工厂采用不分落料、冲孔,均是先制造凸模,再配制凹模,或者反之,这样就需要进行换算。本文根据基准件理论公式,考虑到模具磨损后尺寸变大、变小和不变的三种情况,由基准件向非基准件换算,通过图解分析、公式变换,导出方便、实用的刃口尺寸（A非,B非,C非）计算公式,解决了当先制件为非基准件时,其刃口尺寸计算无理论公式直接套用的问题。     

冲裁模刃口尺寸计算公式

在冲裁模设计中，冲裁模的凸模、凹模刃口尺寸计算公式是根据落料以凹模为基准件配制凸模，冲孔以凸模为基准件配制凹模的原则建立的。但在实际生产中，由于条件和习惯的原因，部分工厂采用不分落料、冲也，均是先制造凸模，再配制凹模，或者反之，这样就需要进行换算。本文根据基准件理论公式，考虑到膜具磨损后尺寸变大、变小和不变的三种情况，由基准件向非基准件换算，通过图解分析、公式变换，导出方便、实用的刃口尺寸（A非，B非，C非）计算公式，解决了当先制件为非基准件时，其刃口尺寸计算无理论公式直接套用的问题。     

管材无模镦粗壁厚变化理论研究

对管材无模镦粗变形速度场及壁厚变化规律进行了理论研究．分析了管材无模镦粗的变形模型、速度场以及壁厚变化的影响因素及影响规律,采用上限法确定了管材无楼镦粗速度场及壁厚变化物理模型,为管材无模镦粗工艺工业化应用奠定基础．     

开式冲孔变形过程的计算机模拟——利用上限法模拟非稳定变形过程研究Ⅰ

本文利用上限法研究了圆坯料开式冲孔变形过程的计算机模拟。由于属非稳定变形过程,所以首先根据工艺实验结果确定工件内的变形流动模式,然后建立变形过程的数学模型。计算机模拟在微机IBMPC/XT上进行。对于任何圆坯料开式冲孔过程,只要输入原始数据和参数,计算机就能迅速而精     

基于正交试验花键冷挤压成形过程参数分析

为保证花键的成形质量，减小模具的试模成本，利用DEFORM-3D软件模拟花键的冷挤压成形过程，采用正交试验对下压速度、摩擦因数和凹模初始硬度参数进行优化分析；利用最优参数对成形载荷及凹模磨损深度的影响规律进行探讨，验证其正交试验结论。结果表明，使成形载荷和花键凹模磨损程度最优的参数组合为摩擦因数0.08和凹模初始硬度63 HRC。该分析为实际生产提供了理论参考，具有一定的指导作用。     

AZ31镁合金双曲率方杯拉深成形的有限元分析及工艺优化

基于ABAQUS软件模拟了AZ31镁合金双曲率方杯的差温拉深成形过程,采用正交实验法探索了多种成形参数对AZ31双曲率方杯成形质量的交互作用,优化得到最佳工艺参数,并进行了试验验证。结果表明:双曲率方杯的板材减薄主要集中在凸模圆角附近;成形参数对最大减薄率的影响顺序依次为:压边间隙、凹模圆角半径、摩擦因数、凸凹模间隙;本实验最佳工艺参数如下:压边间隙为1.2 mm、凹模圆角半径为7 mm、摩擦因数为0.05、凸凹模间隙为1.05 mm;依据最佳工艺参数进行试验验证,产品件表面质量优秀,形状和厚度分布与数值模拟结果相吻合;除凹模圆角附近发生晶粒长大外,产品件各部位微观组织为均匀、细小的等轴晶粒,满足实际生产要求。     

AZ80镁合金管材热挤压工艺及组织性能研究

选用不同的工艺参数对变形镁合金AZ80进行管材热挤压工艺实验研究;对挤压前后材料组织与力学性能的变化进行分析。研究结果表明：热挤压可以显著细化AZ80镁合金的晶粒,而且随着挤压比的增加,晶粒变得更加细小;增大挤压比也可以提高AZ80镁合金的抗拉强度和屈服强度。挤压比为18.2,坯料温度为390℃,模具预热温度360℃,凹模的半模角为60°～70°,可得到均匀的合金组织和良好的力学性能.     

半球面形件拉延变形过程数值模拟

运用有限元模拟软件对不锈钢带凸缘半球面形件进行了拉延过程模拟.分析了凹模圆角半径、摩擦系数对拉延过程的影响,模拟了它们在不同工艺参数下的拉延过程,并从中分析出最佳的工艺参数.从模拟结果中得出当凹模圆角半径R=10mm左右时成形性与拉延质量最佳.     

导盘位置对斜轧穿孔力能参数和扩径量的影响

运用MSC．supefform2005有限元软件对锥形辊穿孔进行三维热力耦合有限元模拟,对管坯中心应力状态进行分析,发现锥形辊穿孔中心应力分布与桶形辊类似。研究导盘位置变化对斜轧穿孔力能参数、内外扩径量的影响;分析导盘前置量和导盘距变化与斜轧穿孔轧制力、顶头力、导盘力和扩径量之间的关系,对了解锥形辊穿孔有重要意义。     

Optimizing loading path and die linetype of large length-to-diameter ratio metal stator screw lining hydroforming

In order to meet the high temperature environment requirement of deep and superdeep well exploitation, a technology of large length-to-diameter ratio metal stator screw lining meshing with rotor is presented. Based on the elastic-plasticity theory, and under the consideration of the effect of tube size, material mechanical parameters, friction coefficient and loading paths, the external pressure plastic forming mechanical model of metal stator screw lining is established, to study the optimal loading path of metal stator lining tube hydroforming process. The results show that wall thickness reduction of the external pressure tube hydroforming(THF) is about 4%, and three evaluation criteria of metal stator screw lining forming quality are presented: fillet stick mold coefficient, thickness relative error and forming quality coefficient. The smaller the three criteria are, the better the forming quality is.Each indicator has a trend of increase with the loading rate reducing, and the adjustment laws of die arc transition zone equidistance profile curve are acquired for improving tube forming quality. Hence, the research results prove the feasibility of external pressure THF used for processing high-accuracy large length-to-diameter ratio metal stator screw lining, and provide theoretical basis for designing new kind of stator structure which has better performance and longer service life.     

受荷方式对钢管混凝土轴压短柱力学性能影响

采用有限元分析软件DIANA对钢管混凝土轴压短柱进行理论分析,并用试验数据验证了有限元模型、材料参数和分析结果的正确性．在此基础上,分析了三种典型受荷方式和黏结强度对钢管混凝土轴压短柱力学性能的影响．三种受荷方式为：1)荷载作用在整个截面上;2)荷载作用在钢管截面上;3)荷载作用在混凝土截面上．有限元分析结果和试验结果及他人试验结果吻合较好．研究结果表明,受荷方式对钢管混凝土轴压短柱的力学性能影响较大;当荷载作用在整个截面上时,黏结强度对轴压短柱的力学性能没有影响;当荷载仅作用在混凝土截面上时。黏结强度对轴压短柱的力学性能影响较大．     

基于神经网络的轧制力预报模型

采用了BP神经网络对热轧无缝钢管穿孔过程中轧制力进行预测，在BP算法学习过程中引入了附加动量法和自适应学习速率，结合Levenberg-Marquardt优化方法，加快了学习时的收敛速度，试验证明，取得了良好的学习和测试效果。研究结果可为斜轧穿孔工具设计和工艺调整提供一定的理论依据，对解决生产中出现的实际问题、开发新产品和新工艺提供有效的指导。     

皮尔格冷轧无缝钢管成形过程组织演变过程研究

皮尔格冷轧技术作为冷轧无缝金属管材最主要的技术手段,具有材料利用率高、截面累积变形量大及加工精度高等特点,以LG-60皮尔格冷轧管机轧制304不锈钢为研究对象建立数值仿真模型,分析不同轧制工艺参数对皮尔格冷轧成形的影响规律。结合轧制实验,截取管材不同的变形段利用金相显微镜、扫描电镜以及X射线衍射仪分析研究了皮尔格冷轧过程中钢管组织演变规律,结果表明：本文所使用工艺参数条件均可以满足管材的塑性变形要求,但在轧制过程中极有可能形成裂纹或其他缺陷。因此通过对皮尔格冷轧仿真过程中轧制力、管材等效应力、残余应力以及外径回弹量等关键参数分析,获得基于送进量、回转角和Q值最优工艺参数,同时,发现轧制过程中随着变形量的增大,试样内部产生了大量位错,晶粒发生了碎化,晶粒尺寸减小,轧制过程中有奥氏体γ相转变为α''-马氏体相。     

Compressional Deformation in Indentation Process for Microlens Array Mold

The structure of a microlens array (MLA) can be formed on copper by an indentation process which is a new manufacture approach we applied here instead of a traditional method to test the material property,thereby work time can be saved.Single-indentation and multi-indentation are both conducted to generate a single dimple and dimples array,namely micro lens and MLA.Based on finite element simulation method,factors affecting the form accuracy,such as springback at the compressed area of one single dimple and compressional deformation at the adjacent area of dimples arrays,are determined,and the results are verified by experiments under the same conditions.Meanwhile,indenter compensation method is proposed to improve form accuracy of single dimple,and the relationship between pitch and compressional deformation is investigated by modelling seven sets of multi-indentations at different pitches to identify the critical pitch for the MLA's indentation processing.Loads and cross-sectional profiles are measured and analyzed to reveal the compressional deformation mechanism.Finally,it is found that MLA at pitches higher than 1.47 times of its diameter can be manufactured precisely by indentation using a compensated indenter.     

Thermoelastohydrodynamic behaviour of inclined-ellipse dimpled gas face seals

The thermoelastohydrodynamic performance of an inclined-ellipse dimpled gas face seal is analyzed. The pressure distributions of the gas film and temperature fields of the seal rings and gas film are presented considering thermal and elastic distortions.Then, the influences of texturing parameters, including dimple inclination angle and dimple depth, on sealing performance are investigated under different operating parameters such as rotational speeds and seal pressures. The results show that face distortions lead to a decrease in the hydrodynamic effect at high rotational speed. The analysis shows that the opening force can decrease by more than 50% as the rotational speed increases from 0 to 35000 r min~(-1). The influence of face distortion on the seal performance, such as opening force and leakage characteristic, gradually increases with the rotational speed.     

硬质合金耐磨堆焊材料断裂与韧性的研究

通过对不同类型硬质合金复合耐磨堆焊材料冲击试验的研究,探讨了影响堆焊层韧性的因素,观察分析了其断口形貌和断裂机理.结果表明,堆焊材料的冲击韧性与断口上硬质合金颗粒的面积分数、堆焊方法以及基体金属的显微组织有关,主要取决基体金属韧性和含量.基体金属的韧性越好、含量越多,堆焊材料的韧性越高.在冲击载荷作用下,基体金属断裂表现为高塑性的韧窝断裂,且存在一定撕裂棱,而硬质合金的断裂为脆性穿晶解理断裂或沿晶断裂.     

Compressional Deformation in Indentation Process for Microlens Array Mold

The structure of a microlens array (MLA) can be formed on copper by an indentation process which is a new manufacture approach we applied here instead of a traditional method to test the material property,thereby work time can be saved.Single-indentation and multi-indentation are both conducted to generate a single dimple and dimples array,namely micro lens and MLA.Based on finite element simulation method,factors affecting the form accuracy,such as springback at the compressed area of one single dimple and compressional deformation at the adjacent area of dimples arrays,are determined,and the results are verified by experiments under the same conditions.Meanwhile,indenter compensation method is proposed to improve form accuracy of single dimple,and the relationship between pitch and compressional deformation is investigated by modelling seven sets of multi-indentations at different pitches to identify the critical pitch for the MLA's indentation processing.Loads and cross-sectional profiles are measured and analyzed to reveal the compressional deformation mechanism.Finally,it is found that MLA at pitches higher than 1.47 times of its diameter can be manufactured precisely by indentation using a compensated indenter.