【摘要】：柔性軋制成形是一種曲面件連續(xù)成形新工藝,是將多點調(diào)形方法與軋制技術(shù)有機結(jié)合,依靠上、下柔性輥間特殊的輥縫分布和柔性工作輥自身旋轉(zhuǎn)來實現(xiàn)板材的三維塑性變形和連續(xù)進給,從而實現(xiàn)三維曲面件無模、連續(xù)、高效成形,具有加工成本低、成形方式靈活、成形范圍廣等優(yōu)點,容易滿足諸多行業(yè)對曲面板類件個性化的需求,特別是在航空航天、艦船、民用工業(yè)等領域有著廣泛的應用前景。本文對柔性軋制成形工藝進行理論分析,通過數(shù)值模擬與實驗驗證相結(jié)合的方法探究柔性軋制成形規(guī)律及工藝參數(shù)的影響規(guī)律,利用正交試驗對主要工藝參數(shù)進行多因素試驗設計,達到優(yōu)化柔性軋制成形工藝的研究目的。本文的具體研究內(nèi)容如下:(1)從塑性力學、幾何學及板料變形角度分析柔性軋制成形工藝原理,分析兩種典型曲面件—凸曲面件及鞍形件的成形特點。結(jié)合塑性成形理論,對成形過程進行力學分析,并分析板料縱向彎曲變形情況�；谏�、下工作輥只能小撓度彎曲的實際情況,建立輥縫控制函數(shù)。(2)建立柔性軋制成形的有限元模型,從橫、縱、厚三向?qū)煞N典型件進行輪廓分析,得到零件曲面光順性良好,驗證了柔性軋制成形輥縫設計的有效性及有限元模型的正確性。通過數(shù)值模擬分析,以成形件橫、縱向曲率為研究指標,得到調(diào)形半徑、最大減薄率以及板厚對鞍形件橫、縱向曲率的影響規(guī)律。(3)在數(shù)值模擬的基礎上,進一步對調(diào)形半徑、最大減薄率及板厚三個主要工藝參數(shù)進行正交試驗優(yōu)化設計,采用極差和方差分析方法對試驗數(shù)據(jù)進行分析,得到各工藝參數(shù)影響成形結(jié)果的主次關(guān)系,對比各工藝參數(shù)對考察指標影響的顯著程度及貢獻率,驗證影響橫、縱向變形因素之間的交互作用,優(yōu)化得出最優(yōu)的工藝參數(shù)組合。正交試驗量化了各工藝參數(shù)對成形結(jié)果的貢獻率,使影響程度更直觀。參數(shù)對成形件形狀影響的研究可以為工作輥形狀調(diào)節(jié)、板形控制等提供理論基礎。(4)柔性軋制成形的相關(guān)實驗研究,對模擬結(jié)果進行實驗驗證。柔性軋制成形凸曲面件及鞍形件兩種典型件,分析實驗件形狀與成形誤差分布規(guī)律,實驗件曲面光順性良好。通過對比實驗,分別研究在不同工藝參數(shù)下,零件曲率及成形誤差規(guī)律,與數(shù)值模擬結(jié)果一致。通過實驗對比驗證了最優(yōu)工藝參數(shù)組合下的零件成形誤差小,質(zhì)量良好,說明建立的正交試驗優(yōu)化是可行的。
[Abstract]:Flexible rolling forming is a new continuous forming process for curved parts, which combines multi-point adjustment method with rolling technology. Special roll gap distribution and flexible work roll rotation are used to realize the three-dimensional plastic deformation and continuous feed of the plate, so that the three-dimensional curved parts can be formed without die, continuously and efficiently, with low processing cost and flexible forming mode. Because of its wide range of forming advantages, it is easy to meet the individualized needs of curved panel parts in many industries, especially in the fields of aerospace, ship, civil industry and so on. In this paper, the flexible rolling forming process is theoretically analyzed, and the influence of the process parameters on the flexible rolling forming process is investigated by the method of numerical simulation and experimental verification. In order to optimize the flexible rolling forming process, the orthogonal test was used to design the main process parameters. The main contents of this paper are as follows: (1) from the angles of plastic mechanics, geometry and sheet metal deformation, the principle of flexible rolling forming process is analyzed, and the forming characteristics of two typical curved surface parts, convex curved parts and saddle parts, are analyzed. Combined with plastic forming theory, mechanical analysis of forming process and longitudinal bending deformation of sheet metal are carried out. Based on the fact that the upper and lower work rolls can only be bent with small deflection, the roll gap control function is established. (2) the finite element model of flexible rolling forming is established, and the contour of two typical parts is analyzed in three directions: transverse, longitudinal and thickness. The results show that the surface fairing is good, which verifies the validity of the roll gap design and the correctness of the finite element model. Through numerical simulation and analysis, the effects of shape adjustment radius, maximum thinning rate and plate thickness on the transverse and longitudinal curvature of saddle parts are obtained by taking the transverse and longitudinal curvature of forming parts as the research index. (3) on the basis of numerical simulation, the radius of shape adjustment is further adjusted. Three main process parameters, maximum thinning rate and plate thickness, are optimized by orthogonal test. The test data are analyzed by means of range and variance analysis, and the primary and secondary relationships between the process parameters and the forming results are obtained. By comparing the significance and contribution rate of each process parameter to the investigation index, the interaction between the influencing factors of transverse and longitudinal deformation was verified, and the optimal combination of process parameters was obtained. The orthogonal test quantifies the contribution rate of each process parameter to the forming result, which makes the influence degree more direct. The study of the influence of parameters on the shape of forming parts can provide a theoretical basis for shape adjustment and shape control of work rolls. (4) the experimental study on flexible rolling forming is carried out and the simulation results are verified by experiments. This paper analyzes the distribution of the shape of the experimental part and the forming error, and shows that the fairing of the curved surface of the experimental part is good. Through comparative experiments, the curvature and forming error of parts under different technological parameters are studied respectively, and the results are in agreement with the numerical simulation results. It is proved by experiments that the forming error is small and the quality is good under the optimal process parameter combination, which shows that the optimization of orthogonal test is feasible.
【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】：TG335

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