【摘要】：汽車傳動(dòng)軸管是傳動(dòng)系統(tǒng)的重要零部件,大型商用汽車的傳動(dòng)軸管一般采用屈服強(qiáng)度為480MPa的普通鋼材制造,為滿足力學(xué)性能要求,傳動(dòng)軸管壁厚較大,影響汽車輕量化。采用高強(qiáng)鋼代替普通鋼材制造軸管具有力學(xué)性能好、節(jié)能減排、節(jié)材效果明顯等優(yōu)點(diǎn),高強(qiáng)鋼傳動(dòng)軸管一般采用輥彎成型、高頻焊接等工藝制造,其中輥彎成型是最基本和重要的成型工藝,對(duì)后續(xù)焊接質(zhì)量也具有重要影響。因此,研究高強(qiáng)鋼汽車傳動(dòng)軸管輥彎成型技術(shù)具有重要的理論意義和應(yīng)用價(jià)值。輥彎成型過程中板坯變形復(fù)雜,涉及材料非線性、幾何非線性、接觸非線性等問題。高強(qiáng)鋼具有材料強(qiáng)度高、回彈大、塑性較差、焊接難等特點(diǎn),其成型難度較普通鋼大。影響高強(qiáng)鋼輥彎成型的因素很多,包括輥形設(shè)計(jì)、工藝參數(shù)等,其中輥形設(shè)計(jì)與管坯變形過程密切相關(guān),對(duì)管坯成型質(zhì)量具有重要影響。因此,研究高強(qiáng)鋼輥彎成型中輥形設(shè)計(jì)方法和管坯變形規(guī)律,揭示高強(qiáng)鋼成型中輥形與成型質(zhì)量之間的關(guān)系,對(duì)于控制管坯回彈變形、管坯邊緣狀態(tài)、管坯成型質(zhì)量和后續(xù)焊接效果具有十分重要的意義。本文主要研究了高強(qiáng)鋼軸管輥彎成型中的輥形設(shè)計(jì)、管坯整體變形行為及邊緣成型規(guī)律。以Φ120×4mm傳動(dòng)軸管為研究對(duì)象,材料為700QZ高強(qiáng)鋼,基于ABAQUS模擬軟件,研究了適合高強(qiáng)鋼軸管輥彎成型的建模方法,通過采用合理的軋輥簡(jiǎn)化手段和成型過程參數(shù)設(shè)置,建立了輥彎成型過程有限元數(shù)值模擬模型,并通過實(shí)驗(yàn)對(duì)板坯截面形狀、開口度和縱向深度進(jìn)行了對(duì)比和驗(yàn)證。以Φ134×4mm高強(qiáng)鋼軸管為研究對(duì)象,采用普通雙半徑法對(duì)輥彎成型中的軋輥進(jìn)行了輥形設(shè)計(jì),揭示了成型中的板坯變形規(guī)律、應(yīng)力應(yīng)變分布特點(diǎn)及成型中存在的應(yīng)力應(yīng)變過大和板坯干涉等問題,分析并提出了第一次輥形優(yōu)化設(shè)計(jì)方案,改進(jìn)了輥縫、立輥和閉口輥的設(shè)計(jì);針對(duì)第一次優(yōu)化方法不能解決成型中存在的立輥組應(yīng)力集中、變形分配不合理問題,在第二次優(yōu)化方法中研究了 W輥形設(shè)計(jì)并應(yīng)用于高強(qiáng)鋼軸管成型,建立了雙W輥與雙半徑輥組合成型系統(tǒng),改善了成型過程中變形分配和立輥組應(yīng)力集中問題。針對(duì)高強(qiáng)鋼成型困難和普通雙半徑成型中應(yīng)力應(yīng)變分布不均、立輥組應(yīng)力集中等問題,本文提出了一種三半徑輥形設(shè)計(jì)新方法,以Φ134×4mm高強(qiáng)鋼軸管為例,對(duì)成型軋輥進(jìn)行了詳細(xì)的輥型設(shè)計(jì),系統(tǒng)分析了成型中應(yīng)力應(yīng)變大小及分布的均勻性、板坯截面厚度變化規(guī)律、立輥組應(yīng)力分布,并與普通雙半徑法的成型結(jié)果進(jìn)行了對(duì)比,研究表明,三半徑成型法在實(shí)現(xiàn)高強(qiáng)鋼板坯變形均勻和改善立輥組應(yīng)力集中等方面具有明顯優(yōu)勢(shì)。研究了單道次W、雙道次W在三半徑成型法中的應(yīng)用,系統(tǒng)分析了雙W組合輥對(duì)應(yīng)力應(yīng)變分布及立輥組區(qū)域應(yīng)力狀態(tài)的影響,為高強(qiáng)鋼傳動(dòng)軸管輥形設(shè)計(jì)提供了新的思路。針對(duì)立輥組應(yīng)力集中問題,分析了普通雙半徑、雙W雙半徑、三半徑成型法在立輥組成型道次中的變形量,揭示了板坯變形分配與區(qū)域應(yīng)力集中間的關(guān)系。研究了輥彎成型過程中實(shí)現(xiàn)邊緣平行對(duì)接和邊緣變形控制的基本方法,分析和對(duì)比了邊緣變形輥和W成型輥對(duì)板坯邊緣受力狀態(tài)的影響,研究了雙W組合輥中實(shí)體板坯內(nèi)外壁的應(yīng)變分布,提出了衡量板坯內(nèi)外壁變形的相對(duì)變形量概念,并對(duì)不同成型輥下的內(nèi)外壁相對(duì)變形量進(jìn)行了對(duì)比,總結(jié)了不同初始成型輥對(duì)邊緣平行對(duì)接的影響;分析了單半徑和雙半徑立輥對(duì)板坯的接觸和受力狀態(tài),針對(duì)雙半徑和三半徑立輥設(shè)計(jì)提出了避免應(yīng)力集中和回彈控制的設(shè)計(jì)方法;分析了普通單半徑閉口輥對(duì)邊緣控制的不足,提出了考慮板坯伸長(zhǎng)、實(shí)現(xiàn)邊緣控制的雙半徑閉口輥形設(shè)計(jì)方法,為輥彎成型中邊緣控制提供了參考思路。
[Abstract]:The drive shaft tube is an important part of the transmission system. The shaft tube of a large commercial vehicle is usually made of ordinary steel with a yield strength of 480MPa. In order to meet the mechanical performance requirements, the wall thickness of the drive shaft is larger and affects the light weight of the automobile. The mechanical properties of the shaft tube made of high strength steel instead of ordinary steel are good in mechanical properties, energy saving and emission reduction. The high strength steel transmission shaft tube is usually made of roll bending and high frequency welding, in which roll bending is the most basic and important molding process, and it has important influence on the quality of subsequent welding. Therefore, it has important theoretical significance and application value to study the bending forming technology of high strength steel automobile shaft tube roll. In the process of roll bending, the slab deformation is complicated, involving nonlinear material, geometric nonlinearity and contact nonlinearity. High strength steel has the characteristics of high material strength, large resilience, poor plasticity, and difficult welding. Its forming difficulty is larger than that of ordinary steel. There are many factors affecting roll shape of high strength steel, including roll shape design, process parameters and so on, among which roll shape The design is closely related to the deformation process of the tube billet, which has an important influence on the quality of the tube billet. Therefore, the design method of the roll shape and the deformation law of the tube blank in the bending of high strength steel are studied. The relationship between the roll shape and the forming quality in the molding of high strength steel is revealed, and the shape of the springback, the edge state of the tube billet, the quality of the tube billet and the subsequent welding are controlled. This paper mainly studies the roll shape design, the whole deformation behavior and the edge forming rule of the high strength steel shaft tube roll forming. The research object is that the shaft pipe of 120 x 4mm is used as the research object, and the material is 700QZ high strength steel. Based on the ABAQUS simulation software, the modeling method suitable for the bending forming of high strength steel shaft tube is studied. The finite element numerical simulation model of roll forming process is established by using reasonable roll simplification and forming process parameters. Through experiments, the section shape, opening and longitudinal depth of the slab are compared and verified. The axial tube of 134 x 4mm high strength steel is used as the study of the image, and the common double radius method is used in the roll bending forming. The roll shape design is carried out. The deformation law of the slab, the distribution characteristic of stress and strain, the excessive stress and strain in the forming and the interference of the slab are revealed. The first roll shape optimization design scheme is analyzed and proposed, and the design of the roll gap, the vertical roll and the closed roll are improved. The first optimization method can not solve the molding. In the second time optimization method, the W roll shape is designed and applied to the high strength steel shaft tube forming. The combined forming system of double W roll and double radius roller is established, which improves the deformation distribution and the stress concentration in the vertical roll group in the forming process. In this paper, a new method of three radius roll shape design is put forward in this paper. In this paper, a new method of three radius roll shape design is put forward. With the example of the shaft pipe of 134 x 4mm high strength steel, the roll shape is designed in detail. The size of stress and strain, the uniformity of the distribution and the thickness variation of the slab section are systematically analyzed. Law, the stress distribution of the vertical roll group is compared with the forming results of the common double radius method. The study shows that the three radius forming method has obvious advantages in realizing the uniform deformation of the high strength steel plate and improving the stress concentration of the vertical roll group. The application of single pass W and double pass W in the three half diameter forming method are studied, and the double W combination roll is systematically analyzed. The influence of the stress and strain distribution and the stress state of the vertical roll group provides a new idea for the design of the roll shape of the high strength steel transmission shaft. According to the stress concentration problem of the vertical roll group, the deformation of the common double radius, the double W double radius and the three radius forming method in the vertical roll form is analyzed, and the deformation distribution of the slab and the stress concentration in the region are revealed. The relationship between the edge deformation and the edge deformation control in the roll forming process is studied. The influence of the edge deformation roll and the W forming roller on the stress state of the edge of the slab is analyzed and compared. The strain distribution in the outer wall of the solid slab in the double W composite roll is studied, and the relative variation of the inner and outer wall deformation of the slab is proposed. The relative deformation of the inner and outer walls under different forming rollers was compared, and the influence of different initial forming rollers on the parallel butt of the edge was summarized. The contact and force state of the single radius and double radius vertical rollers on the slab were analyzed. The setting of the double radius and three radius vertical rollers was put forward to avoid the stress concentration and the Springback Control. By analyzing the shortcomings of the edge control of the ordinary single radius closed roll, the design method of double radius closed roll shape design considering the length of the slab and realizing the edge control is put forward, which provides a reference for the edge control in the roll bending.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG30;U463.2

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