基于Deform和响应曲面法的钢丝拉拔工艺优化

目的对钢丝拉拔过程的成形质量和拉拔力同时进行优化。方法通过Deform-3D软件建立钢丝拉拔第一道次的有限元分析模型,并验证其可靠性。结合建立的有限元模型,采用正交试验设计,寻找钢丝拉拔过程的显著性影响因素,再以显著性因素为变量,以成形质量指标(文中定义为不均匀系数N)和拉拔力P为响应,建立响应曲面模型,对工艺参数进行优化。结果通过正交试验设计分析发现,模具半锥角和压缩率既是不均匀系数N的显著性影响因素,又是拉拔力P的显著性影响因素;通过分析建立的响应曲面模型发现,单独优化一个指标时,会劣化另一个指标,综合考虑两个指标,得到的较优的工艺参数为模具半锥角5°,压缩率17.65%,此时不均匀系数N为0.247,拉拔力P为2593.77N。结论经过验证,建立的有限元模型和响应曲面模型均具有可靠性,可用于钢丝拉拔工艺的研究和优化。

Optimization of Steel Wire Drawing Process Based on Deform and Response Surface Methodology

The work aims to optimize both the forming quality and the drawing force of the wire drawing process. A finite element analysis model of the first pass of steel wire drawing was established with software Deform-3D to verify its reliability. Based on the finite element model, the orthogonal test design was carried out to find the significant influencing factors of the wire drawing process, and then the response surface model was established to optimize the process parameters with the significant factors as variables, the forming quality index (defined as nonuniformity coefficient N) and the drawing force P as response. It was found through the orthogonal test that the half die angle and compression ratio were not only the significant influence factors of the nonuniformity coefficient N, but also the significant influence factors of the drawing force P. By analyzing the response surface model, it was found that when one index was optimized alone, another index would be degraded. Taking two indexes into account, the better process parameters were the half die angle was 5° and the compression ratio was 17.65%. At that time, the nonuniformity coefficient N was 0.247 and the drawing force P was 2593.77 N. After verification, the finite element model and response surface model are both reliable and can be used for the study and optimization of steel wire drawing process.