本文選題：管材　切入點：塑性成形　出處：《吉林大學》2017年碩士論文　論文類型：學位論文

【摘要】：零件的節(jié)材節(jié)能、高精度、高效率化生產(chǎn)是塑性成形的主要發(fā)展方向之一,其中空心件代替實心件是一種有效的節(jié)材節(jié)能化生產(chǎn)方式,因此管件塑性成形方法的研究越來越受關注。多截面異型管件廣泛應用于現(xiàn)代化工業(yè)生產(chǎn),管材塑性成形具有輕量化、近凈成形的優(yōu)點,但該方面文獻研究相對較少。本文以載重車整體驅(qū)動橋殼的軸頭為例來研究多截面異型管件的塑性成形方法,該種橋殼常采用方、矩形管來成形,如何將方、矩形管的端部變?yōu)閳A截面是整體驅(qū)動橋殼成形重點需要解決的問題之一。因此本文主要研究了方、矩形管變圓管的軸頭制坯以及軸頭成形工藝,并取得了如下成果:方管變圓管采用兩道次輥鍛和一次整形輥鍛�；诳招募佸戇^程中常出現(xiàn)管壁增厚、壁厚不均勻現(xiàn)象,在輥鍛成形過程中添加芯模,改善輥鍛件的成形質(zhì)量。由于空心件輥鍛理論的空白,本文在借鑒實心件輥鍛理論的基礎上再結(jié)合DEFORM模擬軟件設計輥鍛模以及芯模,對比分析有無芯模的成形過程、溫度場、管壁厚度、等效應變、載荷分布情況,得出有芯模成形可以使圓管的壁厚均勻化、提高成形精度,減少材料消耗,降低生產(chǎn)成本,提高輥鍛的穩(wěn)定性,有利于汽車輕量化生產(chǎn),而且對空心件輥鍛工藝的研究具有一定的參考價值。根據(jù)圓管直徑介于矩形管長邊與短邊之間的特點,矩形管變圓管采用兩次帶芯模溫擠壓成形即一次外縮內(nèi)擴,一次外縮。通過分析凹模內(nèi)徑和摩擦系數(shù)對成形效果的影響,模擬研究凹模內(nèi)徑、摩擦系數(shù)、擠壓速度、工作帶長度對兩次擠壓過程中最大擠壓力的影響規(guī)律,得出成形效果好且最大擠壓力較小的參數(shù),為管材擠壓模擬參數(shù)的選擇提供了重要參考價值。分析了擠壓過程中金屬流動速度、溫度場、等效應變、行程-載荷的分布規(guī)律,這對管材生產(chǎn)中缺陷產(chǎn)生的位置的預測、模具設計合理性的判斷以及設備噸位的選擇有重要意義。根據(jù)軸頭的結(jié)構特征及坯料形狀,提出4種軸頭擠壓方案,分析各個方案的優(yōu)缺點,確定軸頭溫-冷復合擠壓工藝即溫擠壓、冷整形。以管材縮徑為研究對象,探討了溫度以及摩擦系數(shù)對管坯壁厚增量、端部翹曲、載荷的影響。分析軸頭成形過程中材料堆積、飛邊、折疊,擠壓件與凹模定徑區(qū)間隙、充不滿,固定端鐓粗,這些常見缺陷產(chǎn)生的原因并提出優(yōu)化方案。該工藝將溫擠壓與冷擠壓的優(yōu)點結(jié)合在了一起,它既滿足了軸頭的厚度尺寸,也提高了軸頭的成形精度,節(jié)約了材料,減少了加工工序,為軸頭的生產(chǎn)提供了一種新的思路。
[Abstract]:The energy-saving, high-precision and high-efficiency production of parts is one of the main development directions of plastic forming, in which hollow parts replace solid parts is an effective energy saving production mode. Therefore, more and more attention has been paid to the study of plastic forming methods of pipe fittings. Multi-section special-shaped pipe fittings are widely used in modern industrial production. Plastic forming of pipes has the advantages of light weight and near net forming. But there is relatively little research on this aspect. This paper studies the plastic forming method of multi-section special-shaped pipe by taking the axle head of the integral drive axle housing of the truck as an example. The bridge shell is usually shaped by square and rectangular tubes. Turning the end of rectangular tube into round section is one of the key problems to be solved in the forming of integral drive axle housing. The results are as follows: the square tube adopts two pass roll forging and one shaping roll forging. Based on the phenomenon of tube wall thickening and uneven wall thickness, the core die is added in the process of roll forging, because the tube wall is thickened and the wall thickness is uneven in the process of hollow parts roll forging. To improve the forming quality of roll forgings. Due to the blank of the theory of roll forging for hollow parts, this paper, based on the theory of solid part roll forging, and combining with DEFORM simulation software, designs roll forging die and core die, and analyzes the forming process and temperature field of the die with or without core. The thickness, equivalent strain and load distribution of the tube wall are obtained. It is concluded that the core-die forming can make the wall thickness of the circular pipe even, improve the forming accuracy, reduce the material consumption, reduce the production cost, improve the stability of roll forging, and benefit the light weight production of the automobile. According to the characteristic that the diameter of the circular tube is between the long and short sides of the rectangular tube, the variable circular tube of the rectangular tube is formed by two times of warm extrusion with the die with core, that is, the expansion of the inner part of the tube is the first time, and it has a certain reference value for the research of the roll forging technology of the hollow part. By analyzing the influence of die inner diameter and friction coefficient on forming effect, the influence of die inner diameter, friction coefficient, extrusion speed and working belt length on the maximum extrusion force during twice extrusion is simulated. The parameters with good forming effect and low maximum extrusion pressure are obtained, which provide an important reference value for the selection of parameters for tube extrusion simulation. The distribution of metal flow velocity, temperature field, equivalent strain, stroke and load during extrusion is analyzed. It is of great significance to predict the position of defects in pipe production, to judge the rationality of die design and to select the tonnage of equipment. According to the structural characteristics of shaft head and the shape of blank, four kinds of extrusion schemes for shaft head are put forward. The advantages and disadvantages of each scheme are analyzed, and the temperature extrusion and cold shaping of shaft head are determined. Taking pipe shrinkage as the research object, the effect of temperature and friction coefficient on the increment of wall thickness and end warping of tube billet is discussed. Influence of load. Analysis of material accumulation, flange, folding, clearance between extruder and die, filling, fixed end upsetting, The process combines the advantages of warm extrusion and cold extrusion. It not only satisfies the thickness of shaft head, but also improves the forming accuracy of shaft head and saves material. The processing procedure is reduced and a new way of thinking is provided for the production of shaft head.
【學位授予單位】：吉林大學
【學位級別】：碩士
【學位授予年份】：2017
【分類號】：TG306

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