【摘要】：徑向鍛造技術(shù)在長軸類零件以及具有內(nèi)部結(jié)構(gòu)的管類零件加工中應(yīng)用廣泛,是一種無屑且精密的金屬成形工藝。該工藝可以顯著提高材料的塑形,增強(qiáng)零件力學(xué)性能,同時具有加工精度高、鍛造效率高、材料利用率高、成形質(zhì)量好等優(yōu)點(diǎn)。本文以快速導(dǎo)線連接器的重要零件錐形管為研究對象,進(jìn)行錐管徑向鍛造工藝與數(shù)值模擬研究。錐管兩端都為錐形,且內(nèi)部裝配有零件,對內(nèi)表面質(zhì)量要求比較高,成形過程中無法加入芯棒,只能通過調(diào)整工藝參數(shù),通過外表面變形控制內(nèi)表面質(zhì)量。錐管內(nèi)表面質(zhì)量的好壞,可以通過錐管厚度變化來衡量,錐管厚度變化越均勻,錐管內(nèi)表面錐度越好,與內(nèi)部零件的配合越緊密。針對錐管的成形工藝,本文主要的研究工作包括以下幾個方面:基于ABAQUS有限元軟件建立了錐管徑向鍛造二維軸對稱模型、三維有限元模型,并對工藝參數(shù)進(jìn)行了優(yōu)化,將實(shí)驗(yàn)結(jié)果與模擬結(jié)果進(jìn)行了對比,討論了多錘頭對徑向鍛造鍛件質(zhì)量的影響,對錐管類零件徑向鍛造數(shù)值模擬進(jìn)行了分析研究。首先,通過工藝分析,確定了錐管徑向鍛造成形工藝方案。基于ABAQUS有限元軟件建立錐管二維軸對稱模型,對軸向送進(jìn)量、摩擦因數(shù)利用單因素變量法分析其對錐管徑向鍛造鍛件壁厚變化的影響。將三維有限元模型中卡爪帶動坯料轉(zhuǎn)動轉(zhuǎn)化為公轉(zhuǎn)部件帶動錘頭繞局部坐標(biāo)軸轉(zhuǎn)過一個相等的相對角度,改進(jìn)的模型在保證計(jì)算精確度的前提下可以設(shè)置更大的質(zhì)量縮放系數(shù),大大提高了計(jì)算效率。將實(shí)驗(yàn)結(jié)果與模擬結(jié)果進(jìn)行了對比,驗(yàn)證了三維有限元模型的正確性。其次,利用正交試驗(yàn),研究軸向送進(jìn)量、旋轉(zhuǎn)角度、摩擦因數(shù)對錐管壁厚變化的影響,并以錐管壁厚最大值到未成形端曲線殘差平方和的平均值的最小值為優(yōu)化目標(biāo),獲得了一組最優(yōu)的工藝參數(shù)組合。另外,分析了錐管直壁段長度對錐管厚度變化的影響,并做實(shí)驗(yàn)驗(yàn)證了模擬結(jié)果。然后,在相同工藝參數(shù)條件下,對比二、三、四錘頭對錐管壁厚變化的影響,分析錐管徑向鍛造過程中應(yīng)變、最大徑向鍛打力等信息。最后,基于上述有限元數(shù)值模擬結(jié)果與實(shí)驗(yàn)驗(yàn)證,研究了無法加入芯棒的錐管類零件的徑向鍛造過程。借助正交試驗(yàn),研究軸向送進(jìn)量、旋轉(zhuǎn)角度、摩擦因數(shù)、錘頭錐角對錐管壁厚變化的影響的顯著性,得到了使錐管厚度均勻變化的最優(yōu)工藝參數(shù)組合。利用origin軟件擬合出錘頭錐角與錐管內(nèi)表面錐角之間的關(guān)系式。
[Abstract]:Radial forging technology is widely used in the machining of long shaft parts and tube parts with internal structure. It is a kind of metal forming technology without chip and precision. The process can significantly improve the shape of the material and enhance the mechanical properties of the parts. At the same time, it has the advantages of high machining precision, high forging efficiency, high material utilization rate and good forming quality. In this paper, the diametral forging process and numerical simulation of the tapered tube, an important part of the fast wire connector, are studied. Both ends of the cone tube are conical and parts are assembled inside the tube. The inner surface quality is very high. The mandrel can not be added in the forming process. The internal surface quality can only be controlled by adjusting the process parameters and controlling the internal surface quality through the deformation of the outer surface. The quality of the inner surface of the cone tube can be measured by the change of the thickness of the cone tube. The more uniform the thickness of the cone tube is, the better the taper of the inner surface of the tube is, and the closer the fit with the internal parts is. The main research work of this paper includes the following aspects: based on the ABAQUS finite element software, the two-dimensional axisymmetric model and three-dimensional finite element model of diametral forging of conical tube are established, and the process parameters are optimized. The experimental results are compared with the simulation results, and the influence of multiple hammers on the quality of radial forging is discussed, and the numerical simulation of radial forging for conical tube parts is studied. Firstly, through process analysis, the process scheme of tapered tube forging is determined. Based on the ABAQUS finite element software, a two-dimensional axisymmetric model of the cone tube is established. The influence of the axial feed quantity and friction coefficient on the wall thickness change of the diametral forging of the cone tube is analyzed by using the single factor variable method. In the three-dimensional finite element model, the claw can drive the billet rotation into a rotating component driving the hammer head to turn around a local coordinate axis at an equal relative angle. The improved model can set a larger mass scaling coefficient under the premise of ensuring the accuracy of the calculation. The calculation efficiency is greatly improved. The correctness of the three-dimensional finite element model is verified by comparing the experimental results with the simulation results. Secondly, the influence of axial feed amount, rotation angle and friction coefficient on the wall thickness of cone tube is studied by orthogonal test, and the minimum value of the maximum wall thickness of cone tube to the mean value of the sum of residual square of unformed curve is taken as the optimization objective. An optimal combination of process parameters was obtained. In addition, the influence of the length of straight wall on the thickness of conical tube is analyzed, and the simulation results are verified by experiments. Then, under the same technological parameters, the effects of two, three and four hammers on the wall thickness of the cone tube are compared, and the information of strain and maximum radial forging force during the forging process of the cone tube are analyzed. Finally, based on the numerical simulation results and experimental verification, the radial forging process of cone tube parts which can not be added with mandrel is studied. The effects of axial feed, rotation angle, friction coefficient and hammerhead cone angle on the wall thickness of cone tube were studied by orthogonal test. The optimal process parameters were obtained to make the thickness of cone tube change uniformly. The relationship between the cone angle of the hammer head and the cone angle of the inner surface of the cone tube is fitted by origin software.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG316

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