高精度管材拉拔过程计算机模拟研究

高精度管材是一种内表面质量要求很高,内径尺寸允许偏差很小的管材。研究了高精度管材拉拔模具形式对管材生产的影响。开发了一种新型芯棒,利用MSC.MARC有限元仿真软件,模拟高精度管材的拉拔过程,分析了新型芯棒对高精度管材尺寸精度的影响规律,为研究和生产提供有效的帮助。     

芯棒位置对管材内径尺寸精度影响的有限元模拟

利用MSC.MARC有限元仿真软件模拟了固定短芯棒拉拔时芯棒在变形区中不同位置时的管材拉拔过程,研究芯棒位置不同对管材内径尺寸精度影响的规律.结果表明,芯棒在变形区中位置不同,拉拔管材的内径尺寸缩小量不同,这种变化还与芯棒与模子的配合类型有关.本模拟反映了拉拔过程中管材变形的近似过程,为研究和开发新工艺、新技术提供了有效的工具.     

不同拉拔工艺对管材尺寸精度的影响

高精度管材是一种表面质量（特别是内表面质量）要求很高，内径尺寸允许偏差很小的管材，多用于精密设备。简要概述了目前管材生产现状以及高精度管材的发展前景，分析了不同拉拔工艺对管材尺寸精度的影响．介绍了计算机仿真技术在拉拔工艺研究中的应用及现有模拟结果。     

管材拉拔中的不均匀变形与残余应力

为评价管材拉拔中的不均匀变形 ,提出用管材拉拔前后截面形状变化指数Q描述截面变形的不均匀性。用电阻应变片测试了黄铜管材变形后的表面残余应力 ,用管材截面小圆环法计算了截面径向和周向变形的分布 ,确定了管材拉拔中Q值对管材截面上变形分布及表面残余应力的影响规律。     

冷变形管材残余应力测试与分析

用电阻应变片法测试了变形锡黄铜ＨＳｎ７０－１管材表面的残余应力，分析了拉拔管材变形参数对管材表面残余应力及其他性能指标的影响规律，结果表明，增大管材的减壁变形，可以显著地减小管材表面的拉伸残余应力，当减壁比ｔ０／ｔ１大于１．２时，拉拔管材的残余应力较小，经成品退火后管材晶粒组织细小，采用不同型变形方法生产的管材，其表面残余应力也遵循这一规律，２辊冷轧管材有很大的减壁变形，其表面产生了很大的压应力，     

7075铝合金管材挤压成形及对性能影响

对7075铝合金管材挤压成形进行了实验研究，测试了管材挤压成形时挤压力变化规律和变形程度对挤压后管材力学性能的影响规律，指出，7075铝合金管材挤压成形时必须严格控制坯料温度，模具预温度，润滑方式，挤压速度，挤压比等工艺参数。     

鳍片型钢管拉拔外模的设计

介绍了鳍片型钢管冷拔的成形机理，并分析了无芯棒与有芯棒拔制时的变形力学图、附加应力的变化规律及其危害。通过对比，阐明了在同样条件下，有芯棒拔制时的变形均匀程度好、附加应力小、产品质量稳定， 故建议采用有芯棒拉拔方案。在此基础上，合理拟订拉拔道次及各次减径量，给出了组合式外模的结构形式及型孔尺寸。     

无芯棒拉拔过程应力应变分析及壁厚变化

管材无芯棒拉拔时,直径减小的同时壁厚也会发生改变,其增厚值可达13.2%,甚至更大。但现有文献对无芯棒拉拔过程进行应力应变分析时,通常忽略壁厚的变化,这对预测管件壁厚,从而对工艺参数进行控制不利。该文不同于以往壁厚不变的假设,而是采用应力应变方程统一求解的方法,按增量理论给出壁厚变化的理论解以及应力分布。同时,选取不同的初始直径管坯进行无芯棒拉拔实验,分析变形后出口端壁厚变化规律,并与理论计算结果进行比较。结果表明,随拉拔道次变形量的不断增大,出口端管材的壁厚变化率先增大后减小,但是最终的变形总是增厚,实验结果与理论计算值吻合较好。     

NiTi基形状记忆合金管材组合温拔工艺及组织性能分析研究

NiTi基记忆合金管材在紧固件、连接件和医疗等领域都有广泛的用涂.NiTi基记忆合金无缝管材是一种难加工型材.采用多道次冷轧加中间真空退火工艺生产成本较高.通过热加工工艺生产NiTi基记忆合金管材国际上只有少数几个国家技术过关.为深入研究其变形规律,在我国实现产业化,借助有限元模拟设计了模具、工装和拔制工艺.通过套拉开坯或机械加工管坯和金属芯棒,采用石墨润滑,在60T万能拉压实验机上对碳钢和NiTi形状记忆合金两对组合体进行400～700℃不同温度、10～15%不同到次延伸率、芯棒与管坯间不同间隙和不同长度下的温拔试验.然后加热塑性拉伸金属芯棒,使其减径并从管中取出,芯棒材料与管坯为同一种材料.温拔由一步完成或两步或多步完成,每步温拔之间不做任何处理,每步温拔芯棒要充分地改变,然后进一步延伸.成功地拔制出了表面和内部质量良好的科4mm管材.结果表明该工艺可用于NiTi基记忆合金材加工,也可供成型其他难加工管材参考.为与套拉后制件的组织性能对比研究提供素材,套拉前对管坯组织性能进行了分析.     

管材挤压工艺分析及实验研究

对管材挤压成形进行了工艺分析及实验研究。确定了镁合金、7075铝合金、高温合金等几种材料管材挤压成形工艺参数，分析了管材挤压成形时变形力的变化规律。研究结果表明，管材挤压成形时必须严格控制坯料温度、模具预热温度、润滑方式、挤压速度、挤压比等工艺技术参数。以上工艺参数对挤压力均有不同程度的影响。     

Effect of frictions on cross section quality of thin-walled tube NC bending

1 Introduction Thin-walled tube bending parts have been increasingly used in many industry fields such as aviation, aerospace and automobile for their easy satisfaction in light weight, high strength and low consuming. The numerical controlled(NC) rotar…     

生物医用镍钛记忆合金管材塑性成形研究进展

镍钛形状记忆合金管材在生物医学领域得到了越来越广泛地应用.塑性成形工艺是制造镍钛形状记忆合金管材的重要手段,镍钛形状记忆合金管材的塑性成形工艺方法包括正挤压、反挤压、可变形芯模挤压、无芯模拉拔、固定芯头拉拔、浮动芯头拉拔、可变形芯模拉拔和不可变形芯模拉拔.拉拔工艺仍是目前生产生物医用级镍钛形状记忆合金管材的主要手段.     

Investigation of the formability limit of aluminium tubes drawn with variable wall thickness

Structural aluminium tubes have very important industrial applications, particularly in automobile industry. Tube drawing process is widely used to reduce the outer and inner diameters of tubes. An important issue in the tube drawing process to obtain variable wall thickness is how to determinate and predict its formability limits. Previously published works generally deal with the formability limit of conventional tube drawing based on experimental analysis, analytical method and finite element method. However, in the case of variable wall thickness tubes, there is a lack of knowledge and data in order to predict their limit of formability. In the present study, both theoretical and experimental methods are proposed for estimating the formability limit of the variable wall thickness aluminium tubes used for the transportation purposes. A modification of a conical mandrel was proposed and a special control system for mandrel displacement during the process was used to carry out the drawing tests. During the drawing process, the tube pulling axis was controlled at constant speed while the mandrel was moved to achieve the continuously variable wall thickness. The formability limit in term of minimum wall thickness and maximum area reduction was obtained before tube rupture. These values are useful data for the determination of the extent of deformation during a drawing process that a material can experience without failure. The maximum drawing stress ratio was also determined experimentally. Further, an extension of an upper bound solution developed in previous publications is proposed to predict the drawing stress field. The maximum drawing stress ratio was used as a criterion for fracture analysis. It was shown that the analytical model with its new extension combined to the fracture criterion predicts quite well the thickness and area reduction limit. The experimental studies were completed by examining the microstructure and strain field at the limit state.     

Effect of mandrel on cross section quality of thin-walled tube numerical controlled bending

The effect of mandrel with the structure of ball and socket on the cross section quality of thin-walled tube numerical controlled （NC） bending was studied by numerical simulation method, combined with theoretical analysis and experiment. Influencing factors of the mandrel include the count of mandrel heads, the diameter of mandrel and its position. According to the principle of NC tube bending, quality defects possibly produced in thinwalled tube NC bending process were analyzed and two parameters were proposed in order to describe the cross section quality of thin-walled tube NC bending. According to the geometrical dimension of tube and dies, the range of mandrel protrusion was derived. The finite element model of thin-walled tube NC bending was established based on the DYNAFORM platform, and key technological problems were solved. The model was verified by experiment. The effect of the number of mandrel heads, the diameter of mandrel and the protrusion length of mandrel on the cross section quality of thin-walled tube NC bending was revealed and how to choose mandrel parameters was presented.     

冷轧精密钢管用芯棒的选材和热处理

讨论了冷轧精密钢管的关键工模具冷轧芯棒的工况特点、选材和热处理工艺。分析了GCr15钢冷轧芯棒在制造工艺和实践应用中存在的问题以及9CrSi、Cr12MoV钢的材料特性。提出了冷轧芯棒合理的制造工艺。解决了细长类工具冷轧芯棒在进行热处理变形控制的同时获得高硬度高耐磨性的工艺难题。     

圆管压扁-压弯连续变形过程有限元模型的建立及截面畸变研究

为研究圆管压扁-压弯连续变形过程中的截面畸变,基于有限元软件ABAQUS建立了该过程的三维有限元模型,并实验验证了其可靠性。分析了圆管压扁过程中的截面变化规律及弯曲下模圆角半径、模具与管材间的摩擦系数对成形过程截面畸变的影响。结果表明,圆管压扁过程中形成扁管直壁部分的材料在外层周向压应力、内层周向拉应力的合力作用下出现塌陷。形成扁管圆弧部分的材料在外层周向拉应力、内层周向压应力的合力作用下出现扁化。在无芯轴、有芯轴压扁成形前期,圆弧部分均出现扁化,且无芯轴压扁成形中期,直壁部分出现塌陷。但有芯轴压扁过程中芯轴的支撑作用不但抑制了直壁部分的塌陷,而且还矫正了成形后期圆弧部分的扁化。由于圆管压扁-压弯过程中模具与管材的接触区域始终不大,因此成形过程中弯曲下模圆角半径,及模具与管材间的摩擦系数,对截面畸变影响不显著。     

Y型三辊辊模长芯棒拉拔无缝钢管的工艺研究

研究了利用Y型三辊辊模长芯棒冷拔无缝钢管的减径减壁生产新技术。与常规固定模拉拔相比，辊模拉拨改变了变形区的摩擦条件、速度条件和变形条件，减少了金属与模具间的摩擦，简化了生产工艺。     

大口径空心芯棒用管的研制

简述了芯棒的用途、工作环境、成本及自制大口径空心芯棒的必要性,介绍了利用自身设备优势开发大直径空心芯棒用管的设计思路和开发过程。从坯料成分、尺寸精度、热处理工艺以及市场分析等方面分析了空心芯棒的研发现状,并确定了大口径空心芯棒用管今后的开发方向。     

薄壁管小弯曲半径数控绕弯成形芯模效用的实验研究

薄壁管数控弯曲中带芯头的柔性芯模是提高薄壁管件成形极限和成形精度的关键因素。文章建立了绕弯过程芯模(包括芯棒和芯头)的理论解析模型,包括了芯模直径d、芯棒伸出量e、芯头个数n、芯头厚度k、芯棒/芯头孔心间距p及芯棒圆角半径r等参数的选取公式的推导,获得了不同弯曲规格下的芯模参数取值范围,验证了解析模型的合理性;实验研究了芯模参数对管材失稳起皱、壁厚减薄和截面畸变的影响规律。通过分段抽芯的工艺方法,完成了38mm×1mm×38mm(1D)高难度不锈钢管件的弯曲。