本文選題：復(fù)合工藝 + 微零件�。� 參考：《江蘇大學(xué)》2017年碩士論文

【摘要】：隨著零件輕量化和微型化的發(fā)展,市場對于微型器件的需求日益增加,各種微成形工藝相繼涌現(xiàn)出來,如微拉深、微彎曲、微沖裁、微壓印等。制造涉及多種工藝的微零件時(shí)則需要使用級進(jìn)模以及復(fù)合模。但由于模具制造困難、取出操作性差以及沖頭與凹模的對中等問題,使得微零件的尺寸始終限制在一定的范圍內(nèi)。本文利用激光柔性動(dòng)態(tài)沖擊成形技術(shù),制造出一種可用作墊片,外環(huán)直徑為1.4mm的微碟形零件,實(shí)現(xiàn)了微拉深、微沖裁與微落料的復(fù)合工藝。通過微復(fù)合模具的可行性探究、實(shí)驗(yàn)研究和微碟形零件成形過程的數(shù)值模擬分析了激光柔性動(dòng)態(tài)沖擊成形微碟形零件的技術(shù),主要的工作內(nèi)容和成果如下:(1)建立了激光柔性動(dòng)態(tài)沖擊成形微碟形零件的實(shí)驗(yàn)平臺,設(shè)計(jì)了齊高度微復(fù)合凹凸模、半高度微復(fù)合凹凸模和微復(fù)合凹模這三種不同的微復(fù)合模具。在T2紫銅材料上完成了微碟形零件的制造。利用基恩士三維顯微鏡觀察成形形貌,對成形性能、工藝完成順序、工藝完成度以及零件可取出性這四個(gè)方面進(jìn)行分析。對于齊高度微復(fù)合凹凸模,復(fù)合工藝均可完成,但沖裁斷面的質(zhì)量較低,微碟形零件較難從模具中取出;對于半高度微復(fù)合凹凸模,微沖裁工藝不能完成,微碟形零件仍然較難從模具中取出;對于微復(fù)合凹模,復(fù)合工藝均可完成,工藝完成順序?yàn)槲⒗?微沖裁,微落料,具有較好的表面形貌和斷面質(zhì)量,微零件能夠從模具中取出,因此微復(fù)合凹模較適合用來制造微碟形零件。(2)利用微復(fù)合凹模進(jìn)行實(shí)驗(yàn),對微碟形零件的成形高度、微沖裁的質(zhì)量、工藝類型對尺寸精度的影響、微零件的厚度、軟模厚度對成形過程的影響進(jìn)行了討論,測試并分析了表面粗糙度和試樣的硬度。通過對成形高度的測量,發(fā)現(xiàn)成形高度隨著激光能量的增加先增大后減小。利用三維光學(xué)顯微鏡和掃描電子顯微鏡SEM對零件的直徑尺寸和斷面進(jìn)行分析,發(fā)現(xiàn)微沖裁的直徑尺寸隨著激光能量的增加先增大后減小。在高應(yīng)變率加載下,斷面出現(xiàn)了較大的圓角帶,沒有明顯的光亮帶和斷裂帶。而單獨(dú)沖裁微孔時(shí)出現(xiàn)了較小的圓角帶、光亮帶與毛刺,與復(fù)合工藝產(chǎn)生了差異。微沖裁與微落料的尺寸精度隨著激光能量的變化趨勢類似,但微沖裁的尺寸精度為負(fù)值,微落料的尺寸精度為正值。(3)研究了材料特性、模具特征和激光能量對工件材料的厚度分布規(guī)律的影響,T2紫銅和304不銹鋼的最大減薄率都出現(xiàn)在頸部區(qū)域,最小減薄率分別出現(xiàn)在中間區(qū)域和法蘭區(qū)域。在相同的激光能量下,當(dāng)軟模厚度增加時(shí),工件的成形過程出現(xiàn)了明顯的滯后現(xiàn)象。利用Axio CSM700測量不同區(qū)域的Ra值,發(fā)現(xiàn)法蘭區(qū)域和頸部區(qū)域的表面粗糙度值隨著激光能量的增大而增加,僅在微落料工藝完成后發(fā)生了驟降,而底部區(qū)域的表面粗糙度值隨著激光能量的增大而減小。通過納米硬度測試發(fā)現(xiàn),T2紫銅與304不銹鋼的納米硬度較原材均有提高,平均硬度值均在頸部區(qū)域提升最多。(4)使用ANSYS/LS-DYNA軟件對激光柔性動(dòng)態(tài)沖擊成形微碟形零件的過程進(jìn)行了數(shù)值模擬,探究了模具特征對工藝順序的影響、軟模厚度對成形過程的影響以及成形過程中的回彈,進(jìn)一步解釋了制造過程中的變形行為。
[Abstract]:With the development of lightweight parts and miniaturization, the market demand for micro devices is increasing, a variety of micro forming technology have emerged, such as micro deep drawing, bending, micro blanking, Microimprint. Manufacturing process involves a variety of micro parts when you need to use a progressive die to die. But because the mold and composite manufacturing difficulties, poor operation and remove the punch and die on the medium, so that the micro parts size is always limited to a certain range. By using the laser shock forming flexible dynamic technology, manufacturing a gasket can be used as the outer ring, the diameter is 1.4mm micro disc shaped parts, realize micro deep drawing. Micro blanking and micro composite materials. Through the fall process feasibility of micro composite mold research, experimental research and micro disc parts forming process numerical simulation of laser flexible dynamic impact micro disc parts forming, the main work The contents and results are as follows: (1) the establishment of a flexible dynamic laser shock forming micro disc parts of the experimental platform, design the Qi height micro composite die, half height micro compound punch die and micro composite die of the three different micro composite mold. Manufactured micro disc parts in T2 copper materials. Morphology observation by Kean, forming three-dimensional microscope on the forming performance, process order, process and parts can be taken out of the four were analyzed. For the height of micro embossing composite, composite process can be completed, but at the cutting quality is low, micro disc parts are difficult to remove from the mold in the half height; micro composite die, micro blanking process can not be completed, micro disc parts are still difficult to remove from the mold; for the micro composite die, composite process can be completed, completed in order for the micro deep drawing process, micro blanking, micro drop With material, surface morphology and good quality, the micro parts can be removed from the mold, so micro composite die was suitable for manufacturing micro disc parts. (2) experiments using micro composite die for forming height micro disc parts, the quality of micro blanking process, influence the type of the size accuracy of micro parts, the thickness of soft mold thickness are discussed on the forming process, the test and analysis of the surface roughness and hardness of the samples. The forming height measurement, found forming height with the increase of the laser energy increases first and then decreases. The diameter size and cross section of parts by using three-dimensional optical microscope scanning electron microscopy and SEM analysis, found that the micro blanking diameter with the increase of the laser energy increases first and then decreases. At high strain rate loading section, a larger round belt, no obvious bright band and broken Fracture belt and micro blanking alone appeared smaller fillet with light, belt and burr, makes the difference and combination technology. Micro blanking and micro drop size precision laser energy material with the change trend is similar, but the size precision of micro blanking is negative, micro drop size precision of the material is positive. (3) studied the effect of material properties, mold characteristics and laser energy on the workpiece material thickness distribution, maximum thickness thinning of T2 copper and 304 stainless steel have appeared in the neck region, the minimum reduction rate were found in the middle region and the flange area. Under the same laser energy, when the thickness of the soft mold when increasing the forming process of workpiece has a obvious hysteresis. Using Axio CSM700 to measure the Ra values in different regions of the surface, flange area and neck region roughness value increases with the increase of laser energy, only in the micro blanking process is completed The dips, and the surface roughness of the bottom area decreases with the increase of laser energy. The nano hardness test showed that T2 copper and 304 stainless steel raw material nano hardness is increased, the average hardness value in the neck region up. (4) using the ANSYS/ LS-DYNA software of laser shock forming flexible dynamic process the micro disc shaped parts was simulated and the influence of the characteristics of the mould process sequence, the thickness of the soft mold forming process and springback in the forming process, further explains the deformation behavior of the manufacturing process.

【學(xué)位授予單位】：江蘇大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG665

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