【摘要】：高溫合金薄壁波紋管主要應(yīng)用在航天、航空發(fā)動(dòng)機(jī)的密封裝置,而GH4169高溫合金薄壁管的尺寸精度和力學(xué)性能是波紋管成形的關(guān)鍵。根據(jù)目前的制造工業(yè)和裝備水平,獲取高精度和超薄壁管材成本較高,加工周期長(zhǎng),成品率較低,管坯性能不穩(wěn)定。因此如何獲取機(jī)械性能好、尺寸精度高以及成本低的薄壁管成為了一個(gè)研究重點(diǎn)。為提高產(chǎn)品品質(zhì)以及批量生產(chǎn)時(shí)的穩(wěn)定性,本文采用有限元數(shù)值模擬結(jié)合實(shí)驗(yàn)方法進(jìn)行薄壁管成形工藝參數(shù)的優(yōu)化設(shè)計(jì),另外,本文還提出了采用焊接管坯后,進(jìn)行三輥冷軋與滾珠旋壓獲得管坯的工藝方案,并與現(xiàn)有成形方案進(jìn)行了對(duì)比實(shí)驗(yàn)研究,擬解決現(xiàn)有采用無(wú)縫管坯生產(chǎn)成本高,周期長(zhǎng)的問(wèn)題。本文以三輥軋制實(shí)際工藝為基礎(chǔ),建立與實(shí)際工況一致的三維彈塑性有限元模型,管材從Φ62×1.5mm軋制到Φ45.1×0.65mm,分析工藝參數(shù)如送進(jìn)量、軋制速度、軋槽開(kāi)口度、減薄率對(duì)軋制力的影響,通過(guò)比較不同工藝參數(shù)對(duì)軋制力的影響,優(yōu)化出最終的三輥軋制工藝參數(shù)為進(jìn)給比為2mm/r,減薄率15%,軋輥上的軋槽開(kāi)口度為14°。并且分析三輥軋制的接觸區(qū)域、三輥軋制區(qū)域剪應(yīng)力、軋制力、軸向力的分布規(guī)律,進(jìn)一步了解三輥軋制時(shí)管材的變形規(guī)律。通過(guò)分析管坯在變形區(qū)各階段的變形規(guī)律,獲得了凸耳的產(chǎn)生原因以及解決措施。有限元分析結(jié)果與實(shí)驗(yàn)對(duì)比具有很好的一致性。本文以滾珠旋壓實(shí)際工藝為基礎(chǔ),建立與實(shí)際工況相近的三維彈塑性有限元模型,管材從Φ45.1×0.65mm旋壓到Φ44.8×0.25mm,通過(guò)有限元模擬優(yōu)化工藝參數(shù),得到最終的工藝參數(shù)為進(jìn)給比為進(jìn)給比為1mm/r,減薄率為37.5%。并分析管材在滾珠旋壓下的應(yīng)力應(yīng)變分布規(guī)律。通過(guò)分析隆起區(qū)的應(yīng)力狀態(tài)與受力狀態(tài),研究隆起的成因,以及不同減薄率和不同進(jìn)給比對(duì)旋壓成品質(zhì)量的影響。研究了變形區(qū)的流動(dòng)規(guī)律,了解管材的變形規(guī)律以及所處的應(yīng)力狀態(tài)。采取優(yōu)化的工藝進(jìn)行實(shí)驗(yàn)生產(chǎn),有效地提高了產(chǎn)品品質(zhì)的穩(wěn)定性。本文通過(guò)觀察管坯焊接前后的組織對(duì)比,發(fā)現(xiàn)焊接后的組織是柱狀樹(shù)枝晶組織,然后經(jīng)過(guò)四道次的三輥冷軋,期間配合熱處理后,管材上的焊接位置已經(jīng)難以分辨,觀察其金相組織發(fā)現(xiàn),原始的焊縫組織完全轉(zhuǎn)變?yōu)榫鶆蚪M織。然后經(jīng)過(guò)滾珠旋壓后,管材達(dá)到成品尺寸,金相組織變得更加細(xì)小,尤其是在焊縫位置,焊縫位置比基體組織更加細(xì)小,晶粒度達(dá)到9級(jí),成品管材的屈服強(qiáng)度為458.5MPa、抗拉強(qiáng)度為985.5MPa、斷面收縮率為47.5%,無(wú)縫管坯加工得到的成品管材沒(méi)有明顯差別,均達(dá)到使用要求。
[Abstract]:Thin-wall corrugated tubes of superalloy are mainly used in the sealing devices of aerospace and aero-engine, while the dimensional accuracy and mechanical properties of GH4169 superalloy thin-walled tubes are the key to forming the corrugated tubes. According to the current manufacturing industry and equipment level, the production cost of high precision and ultra-thin wall pipe is high, the processing period is long, the finished product rate is low, and the performance of tube billet is unstable. Therefore, how to obtain thin-walled tubes with good mechanical properties, high dimensional accuracy and low cost has become a research focus. In order to improve product quality and stability in batch production, this paper adopts finite element numerical simulation combined with experimental method to optimize the process parameters of thin-walled tube forming. The process scheme of cold rolling and ball spinning with three rollers was carried out to obtain tube billet, and compared with the existing forming scheme, the problems of high production cost and long period of production of seamless tube blank were solved. Based on the practical technology of three-roll rolling, a three-dimensional elastic-plastic finite element model is established in accordance with the actual working conditions. The tube is rolled from 桅 62 脳 1.5mm to 桅 45.1 脳 0.65 mm. The process parameters such as feed rate, rolling speed, and slot opening degree are analyzed. By comparing the effect of different process parameters on rolling force, the final three-roll rolling process parameters are optimized as feed ratio of 2 mm / r, thinning rate of 15 and groove opening degree of 14 擄. The contact area of three-roll rolling, the distribution law of shear stress, rolling force and axial force in three-roll rolling area are analyzed, and the deformation law of tube during three-roll rolling is further understood. By analyzing the deformation law of tube billet in each stage of deformation zone, the causes and solutions of convex ear are obtained. The results of finite element analysis are in good agreement with the experimental results. Based on the actual process of ball spinning, a three-dimensional elastic-plastic finite element model is established, which is close to the actual working conditions. The tube is spun from 桅 45.1 脳 0.65mm to 桅 44.8 脳 0.25mm, and the process parameters are optimized by finite element simulation. The final process parameters are feed ratio of 1 mm / r and thinning rate of 37. 5%. The distribution of stress and strain of pipe under ball spinning is analyzed. By analyzing the stress state and the stress state in the uplift area, the causes of the uplift and the influence of different thinning rate and feed ratio on the quality of spinning products are studied. The flow law of the deformation zone is studied, and the deformation law and the stress state of the pipe are understood. The stability of the product quality is improved effectively by adopting the optimized technology to carry on the experiment production. By observing the microstructure of tube billet before and after welding, it is found that the microstructure after welding is columnar dendritic structure, and then after four passes of three rolls cold rolling, the welding position on the tube is difficult to distinguish after heat treatment. The metallographic structure of the weld was observed and the original weld microstructure was completely transformed into uniform microstructure. Then after the ball spinning, the tube reaches the finished size, and the metallographic structure becomes smaller, especially in the weld line, where the weld is smaller than the matrix, the grain size reaches 9, and the yield strength of the finished pipe is 458.5 MPA. The tensile strength is 985.5 MPa and the cross section shrinkage is 47.5%. The finished tubes produced by seamless tube blank processing have no obvious difference and all meet the requirements of application.
【學(xué)位授予單位】：沈陽(yáng)工業(yè)大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2016
【分類號(hào)】：TG457.6;TG306

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本文編號(hào)：2397256