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超半球壳体多道次拉深旋压工艺研究 总被引:3,自引:1,他引:2
针对1060超半球壳体基于板坯多道次拉深旋压进行成形性分析,提出两模法和两轮法的旋压成形试验方案,并设计不同旋压试验方案的芯模和旋轮工装.通过MC2000型数控录返旋压机,分别采用R13、R20和R25、R8不同圆角半径的圆弧式旋轮对1060板坯进行两模法和两轮法的多道次拉深旋压成形试验.两模法旋压毛坯件的凸缘边减薄严重,成形效果差;两轮法旋压采用R25旋轮4道次快速进给,R8旋轮4道次中低速精整旋压的旋压工艺,其旋压件贴模度高,成形效果好.试验结果表明:两轮法旋压工艺能实现板坯经多道次拉深旋压成形为超半球壳体.通过降低芯模转速,调整进给比和降低道次减薄率,可以消除旋压成形过程中出现的反挤、波纹和起皮等缺陷. 相似文献
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基于动力显式有限元软件,以电磁离合器皮带轮为侧,开展了两个工序的旋压成形工艺的数值模拟,研究了旋压成形过程中材料变形情况,对成形件的应力应变分布进行了分析。模拟结果表明:采用旋压成形工艺,通过设置合理的进给量、芯模转速等参数,成形出的零件不仅形状和尺寸满足要求,而且芯模和旋轮所受载荷不大,旋轮最大载荷为540kN,芯模最大载荷为19kN。该研究对旋压带轮的非线性有限元分析和实际生产中设备的选择具有一定的参考和实用价值。 相似文献
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《机械制造与自动化》2016,(1)
设计了超半球壳体基于板坯多道次拉深旋压成形的芯模、旋轮和尾顶座等工装,并针对套轴式尾顶座和内孔定位式尾顶座进行了旋压工艺试验。结果表明,增大尾顶座型面顶部圆弧,增加平面过渡段和圆弧过渡段,可避免旋压工件顶部撕裂;降低芯模转速,调整进给比和降低道次减薄率,能够消除旋压成形过程中的旋压反挤和波纹缺陷。 相似文献
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《现代制造技术与装备》2016,(8)
应用Deform 3D软件建立单旋轮椭圆筒形弹塑性有限元模型,通过设置旋轮绕旋轮轴自转、绕芯模主轴公转和沿芯模主轴方向偏移的运动,合成了椭圆筒形件运动轨迹。采用Dynaform软件反求毛坯尺寸,通过有限元模拟,获得了椭圆筒形件旋压过程中应力应变的分布规律,分析了毛坯形状对成形过程的影响。结果表明:旋压对已加工区的影响很小,并不易在后面即将加工的区域产生材料的堆积,最大等效应力变化不大;椭圆长径过渡到椭圆短径的区域内周向形状不均匀最显著,该区域内等效应变大;椭圆筒形件的旋压在实际生产过程中可以采用Dynaform反求出的毛坯为基础,根据具体情况进行修改和完善。 相似文献
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旋轮与芯模间隙是影响旋压件成形质量的重要工艺参数。离合器毂的内外齿形在旋压成形中易出现齿侧壁呈弧形、齿顶圆角不饱满等缺陷,提出采用齿侧壁弧形度?、齿顶圆角不饱满度χ等来定量表征上述缺陷的大小,并基于有限元软件ABAQUS对内外齿旋压成形过程进行了数值模拟,获得了旋轮与芯模间隙对齿侧壁呈弧形、齿顶圆角不饱满等缺陷的影响规律,并获得了特定条件下的旋轮与芯模间隙的最佳值。结果表明,随着旋轮与芯模间隙的减小,齿侧壁弧形度?、齿顶圆角不饱满度χ随之减小;当旋轮与芯模间隙值取齿顶壁厚的公称尺寸与下极限尺寸的中间值时,可满足齿形壁厚要求并最大限度改善成形缺陷。有限元模型结果与成形试验结果吻合度良好。 相似文献
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钛合金薄壁壳体强旋热力耦合有限元分析 总被引:5,自引:1,他引:4
钛合金薄壁壳体强力热旋是一个多因素耦合作用下的复杂成形过程.合理的有限元模型建立是获得该成形过程中温度场、应力场和应变场等信息的关键,从而为揭示其成形机理、合理选择工艺参数和提高成形质量提供依据.在合理地施加温度边界条件模拟外加热源,并考虑各种热效应的基础上,基于通用有限元软件ABAQUS的dynamic、temp-disp和explicit模块建立符合实际的钛合金薄壁壳体强旋热力耦合三维弹塑性有限元模型,分析TA15钛合金薄壁壳体热旋过程中温度场、应力场、应变场和壁厚的分布及旋轮圆角半径对贴模性能的影响.结果表明,摩擦生热和接触换热的作用使在旋压区沿厚度方向形成较大的温度梯度,产生明显的不均匀变形;等效应力最大值前期大多在圆角过渡区,后期大多在旋轮与板料接触区,且后期板料表面出现应力集中;越靠近零件口部,不贴模趋势越明显;随着旋轮圆角半径减小,贴模性能越好. 相似文献
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以发动机的锡青铜连杆衬套为研究对象,运用DEFORM-3D有限元软件对连杆衬套毛坯的无错距强力旋压过程进行了数值模拟。根据模拟结果,重点分析了在旋压过程中的金属流动速度规律、旋轮的受力以及毛坯的等效应力应变的分布情况。得出了旋压过程中毛坯径向和切向流动速度、大小和方向相似,与毛坯壁厚中心点的流动速度始终相反的正弦分布规律,旋轮所受径向和切向力分布相似且轴向受力最小,旋压过程中等效—应力应变主要分布在旋轮与毛坯的接触区域,远离接触区域的等效—应变较小,毛坯内部存在残余应力等。 相似文献
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工艺参数对平板毛坯普旋成形的影响规律 总被引:3,自引:0,他引:3
基于ABAQUS/Explicit平台建立了符合实际的普旋三维仿真模型,利用此模型对平板毛坯普旋成形过程进行了模拟,研究了旋轮进给率、旋轮圆角半径、旋轮入旋角、板料厚度4个关键参数对平板毛坯普旋(第一道次)成形过程及旋压件质量的影响。结果表明:入旋角对板料的壁厚变化有较大的影响;旋轮圆角半径和板料厚度仅对板料的壁厚减薄率影响较大,对板料的壁厚增厚率影响很小;当旋轮进给率的值较小时,旋轮进给率对普旋成形过程影响不大。基于以上研究,最后得到了合理的工艺参数取值。 相似文献
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筒形件强力内旋压有限元模拟 总被引:6,自引:0,他引:6
采用动态显式有限元程序LS DYNA3D对强力内旋压变形过程进行了数值模拟 ,并对有限元建模提出了一些自己的看法。分析了毛坯周向、轴向、径向的应力应变分布及变化过程 ,对强力内旋压变形过程建立了整体的认识。分析了工艺参数不合理时产生内表面裂纹的主要原因。 相似文献
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Q. X. Xia Z. Y. Lai Hui Long X. Q. Cheng 《The International Journal of Advanced Manufacturing Technology》2013,68(9-12):2461-2470
The noncircular spinning is one of the recent breakthroughs of the traditional spinning processes. The spinning force is one of the important parameters for designing the spinning equipment and one of the main factors influencing the forming quality of spun parts. The variation of spinning force during noncircular spinning is considerably different from that of the conventional spinning due to the high-speed reciprocating movement of the roller induced by the variable spun workpiece profile. This paper presents an experimental investigation of spinning force characteristics of a hollow part with triangular cross sections using an octagon ring transducer based on electrical measuring method. A series of experiments using profiling driving spinning method was carried out to study the effects of the main process parameters, such as the roller feed rate, blank thickness–diameter ratio, and mandrel rotational speed, on the spinning force characteristics. The important characteristics of the force components of noncircular spinning were discussed based on the electrical measuring results. Furthermore, the variations of force components were compared with those obtained in the cases of conventional spinning and 3D non-axisymmetrical spinning. The results show that different from the conventional spinning and similar to the 3D non-axisymmetrical spinning, the three components of spinning force along the axial, radial, and tangential direction of roller vary periodically with the mandrel rotational angle. Different from the conventional and the 3D non-axisymmetrical spinning, the maximum spinning force is related to the mandrel rotational speed, even if the feed rate of roller remains constant, and increases with the increase of the mandrel rotational speed. 相似文献
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Z. Jia Z. R. Han Q. Xu W. F. Peng Q. M. Kong 《The International Journal of Advanced Manufacturing Technology》2015,79(9-12):1689-1698
In view of the importance of the surface quality in the application to the square section die-less spinning, the effects of several key parameters which include roller path, half-cone angle, and roller nose radius on the surface quality are investigated. Through the geometric model of residual height, the effect law of the roller path is obtained: the surface quality increases with the decrease of the axial distance of two adjacent slices. Then the finite element model of the square section die-less spinning is established, and the normal force and axial strain states in the deforming process are adopted to predict the relationship between the surface quality and the half-cone angle. Combined with the residual height model and finite element analysis, the roller nose radius’ effect on the surface quality is also obtained. Enlargement of the two parameters can improve the surface quality. All the analysis results are verified by the surface waviness test of the specimens from the workpiece after spinning. 相似文献
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An analysis of force distribution in shear spinning of cone 总被引:1,自引:0,他引:1
Ming-Der Chen Ray-Quan Hsu Kuang-Hua Fuh 《International Journal of Mechanical Sciences》2005,47(6):902-921
An analytic model for calculation of shear spinning force incorporate factor of over-roll (press down) of the blank is derived. The effects of blank thickness, roller nose radius, mandrel revolution and roller feed on the spinning force are discussed. Results obtained from calculation were compared with the experiment and other theoretical predictions. It is found that the present findings yield optimum results. 相似文献