【摘要】：旋壓成形是實(shí)現(xiàn)薄壁回轉(zhuǎn)體類零件的少無(wú)切削加工先進(jìn)制造技術(shù),以其產(chǎn)品精度高、工藝柔性好、節(jié)約材料、易于實(shí)現(xiàn)機(jī)械化與自動(dòng)化等諸多優(yōu)點(diǎn)而成為塑性成形技術(shù)的重要發(fā)展方向。但普通旋壓工藝生產(chǎn)特定工件需要配備特定芯模,應(yīng)用于多品種、小批量的生產(chǎn)時(shí)受到限制。近年來(lái)的無(wú)芯模旋壓成形雖然脫離了特定芯模的限制,但由于板料單面受力,造成加工不穩(wěn)定,加工件易產(chǎn)生明顯的回彈變形,形狀精度存在明顯誤差。針對(duì)上述技術(shù)難題,本文提出了采用輔助支撐的方式對(duì)曲母線件進(jìn)行無(wú)芯模旋壓成形,增大了板料的塑性變形,提高了成形件的形狀精度。本文的主要內(nèi)容和貢獻(xiàn)如下:(1)基于ANSYS/LS-DYNA有限元軟件顯示動(dòng)態(tài)方法構(gòu)建了無(wú)芯模旋壓成形工藝綜合仿真模型:通過(guò)提取加工中的關(guān)鍵部件尺寸,建立了符合實(shí)際曲母線件無(wú)芯模旋壓的綜合仿真模型,并通過(guò)能量法和實(shí)驗(yàn)對(duì)比法對(duì)模型進(jìn)行了有效性驗(yàn)證,為后續(xù)基于輔助支撐的無(wú)芯模曲母線件旋壓研究奠定了基礎(chǔ)。(2)提出了基于輔助芯模支撐的無(wú)芯模旋壓方法:通過(guò)采用與曲母線輪廓初始段相契合的輔助芯模進(jìn)行支撐,與無(wú)支撐的無(wú)芯模旋壓進(jìn)行對(duì)比,采用仿真與實(shí)驗(yàn)對(duì)比的方式,研究了基于輔助芯模支撐的無(wú)芯模旋壓方法對(duì)板料成形形狀精度及壁厚減薄的影響。實(shí)驗(yàn)證明輔助芯模支撐無(wú)芯模旋壓的最大形狀誤差為8.11mm,比無(wú)支撐的無(wú)芯模旋壓提高了 81.94%,平均形狀誤差為1.60mm,比無(wú)支撐的無(wú)芯模旋壓提高了 92.45%。并通過(guò)對(duì)三條加工輪廓曲線的仿真和實(shí)驗(yàn)加工,對(duì)比加工件的形狀和壁厚精度,實(shí)驗(yàn)證明三條輪廊曲線輔助芯模支撐無(wú)芯模旋壓加工的最大形狀誤差的算術(shù)平均值為6.45mm,平均形狀誤差的算術(shù)平均值為1.61mm。說(shuō)明輔助芯模支撐的無(wú)芯模旋壓方法對(duì)板料成形整體彎折影響較大,但對(duì)凹凸程度較大的曲母線,加工中會(huì)出現(xiàn)過(guò)變形。(3)提出了基于輔助旋輪脈動(dòng)支撐和隨動(dòng)支撐的無(wú)芯模旋壓方法:將板料在徑向方向上的變形過(guò)程看成板料的局部變形,沿徑向方向劃分為若干個(gè)小段,并對(duì)每個(gè)小段用輔助旋輪進(jìn)行支撐。采用仿真和實(shí)驗(yàn)對(duì)比的方式,分別對(duì)三條曲母線輪廓進(jìn)行加工,對(duì)比加工件的形狀和壁厚精度,研究了基于脈動(dòng)支撐和隨動(dòng)支撐的無(wú)芯模旋壓方法對(duì)板料成形形狀精度及壁厚減薄的影響。實(shí)驗(yàn)證明輔助旋輪脈動(dòng)支撐無(wú)芯模旋壓加工的最大形狀誤差的算術(shù)平均值為19.66mm,平均形狀誤差的算術(shù)平均值為10.19mm,隨動(dòng)支撐無(wú)芯模旋壓加工的最大形狀誤差的算術(shù)平均值為19.68mm,平均形狀誤差的算術(shù)平均值為9.80mm,但加工件形狀與目標(biāo)形狀相仿,無(wú)過(guò)變形產(chǎn)生。(4)提出了基于復(fù)合脈動(dòng)支撐和復(fù)合隨動(dòng)支撐的無(wú)芯模旋壓方法:綜合了輔助芯模支撐和輔助旋輪支撐在板料成形中的優(yōu)勢(shì),提出了同時(shí)采用輔助芯模和輔助旋輪進(jìn)行復(fù)合支撐的無(wú)芯模旋壓方法。采用仿真和實(shí)驗(yàn)對(duì)比的方式,分別對(duì)三條曲母線輪廓進(jìn)行加工,對(duì)比加工件的形狀和壁厚精度,研究了基于復(fù)合脈動(dòng)支撐和復(fù)合隨動(dòng)支撐的無(wú)芯模旋壓方法對(duì)板料成形形狀精度及壁厚減薄的影響。實(shí)驗(yàn)證明復(fù)合脈動(dòng)支撐無(wú)芯模旋壓加工的最大形狀誤差的算術(shù)平均值為8.87mm,平均形狀誤差的算術(shù)平均值為3.70mm;復(fù)合隨動(dòng)支撐無(wú)芯模旋壓加工的最大形狀誤差的算術(shù)平均值為4.55mm,平均形狀誤差的算術(shù)平均值為1.37mm,無(wú)過(guò)變形產(chǎn)生,成形效果為最優(yōu)。(5)對(duì)基于五種輔助支撐方式的無(wú)芯模旋壓方法進(jìn)行了綜合對(duì)比,并對(duì)最優(yōu)成形方式進(jìn)行了應(yīng)用實(shí)例驗(yàn)證。從加工件整體及部分的輪廓形狀精度及壁厚減薄情況深入分析了各種支撐方式對(duì)產(chǎn)品加工的綜合影響,并將輔助支撐對(duì)無(wú)芯模旋壓加工的影響程度進(jìn)行了量化表示。最后,對(duì)最優(yōu)方式的復(fù)合隨動(dòng)支撐無(wú)芯模旋壓方法采用五種不同的加工輪廓曲線進(jìn)行了實(shí)驗(yàn)加工,實(shí)例加工件的最大形狀誤差在5.91mm左右,平均形狀誤差在2.48mm左右,最小壁厚在1.19mm左右,最大壁厚減薄率在36.68%左右,平均壁厚減薄率在20.14%左右。進(jìn)一步驗(yàn)證了復(fù)合隨動(dòng)支撐在無(wú)芯模旋壓加工不同曲母線件上的加工柔性。
[Abstract]:Spinning and forming is an advanced manufacturing technology for machining thin-wall rotary body parts, and has the advantages of high product precision, good process flexibility, material saving, easy realization of mechanization and automation, and the like, and becomes an important development direction of the plastic forming technology. but the common spinning process is required to be provided with a specific core die for the production of a specific workpiece, and is applied to the production of a plurality of varieties and small batches. In recent years, the non-core die spinning formation has been limited by the specific core die, but the processing is not stable due to the single-side stress of the sheet, and the workpiece is easy to produce obvious springback deformation, and the shape precision has obvious error. In view of the above technical problems, this paper puts forward the non-core die spinning forming of the curved bus bar by means of auxiliary support, and the plastic deformation of the sheet is increased, and the shape precision of the forming part is improved. The main content and contribution of this paper are as follows: (1) Based on the ANSYS/ LS-DYNA finite element software display dynamic method, a comprehensive simulation model of the non-core die spinning forming process is built: by extracting the key components in the process, a comprehensive simulation model of the non-core die spinning of the actual curved generatrix is established, The validity of the model is verified by the energy method and the experimental comparison method. (2) a non-core die spinning method based on an auxiliary core die support is provided, The influence of the core die-free spinning method on the shape precision and the thickness of the wall is studied. The experimental results show that the maximum shape error of the core-die-supported die-free spinning is 8.11mm, the spinning of the non-supported core-free die is improved by 81.94%, the average shape error is 1.60mm, and the spinning of the non-supported die-free die is improved by 92.45%. The results show that the arithmetic mean value of the maximum shape error of the three-wheel gallery curve auxiliary core die to support the non-core die spinning process is 6.45mm, and the arithmetic mean value of the average shape error is 1.61mm. The non-core die spinning method of the auxiliary core die support has great influence on the whole bending of the sheet metal forming, but the bending bus with a large degree of concave and convex is deformed in the processing. (3) The non-core die spinning method based on the auxiliary rotary wheel pulse support and follow-up support is proposed: the deformation process of the plate in the radial direction is regarded as the local deformation of the sheet material, the radial direction is divided into a plurality of small sections, and the auxiliary rotating wheel for each small section is supported. By means of simulation and experimental comparison, three curved bus lines are processed, the shape and the wall thickness precision of the work piece are compared, and the influence of the non-core die spinning method based on the pulse support and the follow-up support on the shape precision and the thickness of the wall is studied. The experimental results show that the arithmetic mean value of the maximum shape error of the non-core die spinning process of the auxiliary rotating wheel is 190.66mm, the arithmetic mean value of the average shape error is 10.19mm, and the arithmetic mean value of the maximum shape error of the follow-up support non-core die spinning process is 19.68mm, The arithmetic mean of the mean shape error is 9.80mm, but the shape of the work piece is similar to the shape of the target, and no deformation occurs. (4) The non-core die spinning method based on composite pulse support and composite follow-up support is proposed: the advantages of the auxiliary core die support and the auxiliary rotating wheel support in the sheet metal forming are integrated, and the core die spinning method with the auxiliary core die and the auxiliary rotating wheel for composite support is put forward. By means of simulation and experimental comparison, three curved bus lines are processed, the shape and the wall thickness precision of the work piece are compared, and the influence of the core-free die spinning method based on the composite pulse support and the composite follow-up support on the shape precision and the thickness of the wall is studied. and the arithmetic mean value of the maximum shape error of the composite follow-up support non-core die spinning process is 4.55mm, The arithmetic mean value of the average shape error is 1. 37mm, no deformation is generated, and the forming effect is optimal. (5) The method of non-core die spinning based on five auxiliary support modes is compared, and the application example verification is applied to the optimal forming mode. In this paper, the comprehensive influence of various kinds of support methods on the product processing is deeply analyzed from the precision of the profile and the thickness of the wall in the whole and part of the work piece, and the degree of influence of the auxiliary support on the non-core die spinning process is quantified. In the end, five different machining profile curves were used for the composite follow-up support of the best mode. The maximum shape error of the case was about 5.91mm, the average shape error was about 2.48mm, and the minimum wall thickness was about 1. 19mm. The thinning rate of the maximum wall thickness is about 36.68%, and the thinning rate of the average wall thickness is about 20. 14%. and the processing flexibility of the composite follow-up support on the different curved bus bars is further verified.
【學(xué)位授予單位】：浙江大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG306

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