發(fā)布時(shí)間：2018-07-23 18:45

【摘要】：帶內(nèi)環(huán)筋、薄壁是曲母線筒形件廣為采用的結(jié)構(gòu)形式,是在保證零件剛度、強(qiáng)度不降低的情況下減輕重量的首選結(jié)構(gòu)形式。本課題以鋁合金殼體為研究對(duì)象,研究帶內(nèi)環(huán)向加強(qiáng)筋薄壁殼體零件的內(nèi)旋壓成形,通過有限元數(shù)值模擬和試驗(yàn)研究,分別對(duì)小端起旋和大端起旋兩種內(nèi)旋壓成形工藝及制品的組織與性能進(jìn)行了研究。采用ABAQUS軟件對(duì)異形薄壁殼體小端起旋和大端起旋兩種內(nèi)旋壓成形工藝進(jìn)行了有限元模擬,對(duì)其旋壓力和變形情況進(jìn)行了計(jì)算分析。采用小端起旋的預(yù)成形-終成形旋壓工藝,可獲得變形均勻的圓筒形薄壁件。這種旋壓工藝的徑向旋壓力最大,軸向旋壓力次之,切向旋壓力最小。與徑向旋壓力相比,切向旋壓力基本可以忽略不計(jì)。在殼體大端的后端框和中間段蒙皮部分的旋壓成形過程中,其旋壓力存在平臺(tái)區(qū),成形過程平穩(wěn);在殼體小端前端框部分的旋壓成形過程中,旋輪的軸向行程越大,減薄率越大,旋壓力越大,殼體旋壓成形的最大旋壓力出現(xiàn)在這一過程中。若將大端固定,可以實(shí)現(xiàn)擴(kuò)徑旋壓,但在殼體的蒙皮與前端框的過渡區(qū)域出現(xiàn)變形不穩(wěn)定區(qū)。通過對(duì)某內(nèi)環(huán)筋薄壁殼體小端起旋和大端起旋兩種旋壓工藝試驗(yàn),分別研究了大端和小端起旋兩種內(nèi)旋壓工藝的成形規(guī)律。采用大端和小端起旋工藝成形曲母線薄壁殼體時(shí),存在如下兩種工藝:一是在實(shí)現(xiàn)擴(kuò)徑的同時(shí),壁厚基本保持不變;二是在擴(kuò)徑的同時(shí),壁厚進(jìn)行減薄。對(duì)于大端起旋,當(dāng)模具半錐角小于毛坯半錐角時(shí),其壁厚減薄規(guī)律應(yīng)符合正弦律,而小端起旋的壁厚減薄規(guī)律不受正弦律約束。根據(jù)正交試驗(yàn)結(jié)果確定的內(nèi)旋壓成形工藝參數(shù)分別為:進(jìn)給比0.6mm/r,減薄率25%,旋輪圓角半徑6mm,旋輪安裝角25°。通過旋壓試驗(yàn)確定的帶內(nèi)環(huán)筋薄壁殼體小端起旋工藝流程為:毛坯下料→毛坯加工→退火處理→預(yù)成形→淬火→終成形→零件加工。與之對(duì)應(yīng)的旋壓工藝參數(shù)分別是:預(yù)成形的最大壁厚減薄率25%,終成形的最大減薄率為10%;旋輪圓角半徑6mm,旋輪進(jìn)給比0.6mm/r,主軸轉(zhuǎn)速50r/min。試驗(yàn)件的壁厚差為±0.05mm,圓度為0.15mm。對(duì)某制品薄壁殼體旋壓試驗(yàn)件蒙皮段的微觀組織和力學(xué)性能進(jìn)行了測試。測試結(jié)果表明,退火-旋壓工藝成形的制品晶粒比較細(xì)小,尺寸在1μm~5μm之間,但強(qiáng)度不滿足設(shè)計(jì)要求;而預(yù)成形-終成形結(jié)合中間淬火工藝成形制品的晶粒較大,尺寸在15μm~20μm之間,總變形量越大,晶粒尺寸越細(xì)小,其抗拉強(qiáng)度滿足360MPa的設(shè)計(jì)要求;內(nèi)旋壓所有試驗(yàn)件在切向上均有纖維組織產(chǎn)生,總變形量越大,切向纖維組織越明顯;退火—旋壓工藝成形的制品殘余應(yīng)力值較小,預(yù)成形-終成形結(jié)合中間淬火工藝旋壓制品殘余應(yīng)力值相對(duì)較大,旋壓制品的殘余應(yīng)力均為壓應(yīng)力。對(duì)內(nèi)環(huán)筋薄壁殼體內(nèi)旋壓成形工藝的有限元數(shù)值模擬和試驗(yàn)研究,不僅為確定某鋁合金薄壁殼體旋壓成形工藝、實(shí)現(xiàn)批量生產(chǎn)提供了依據(jù),而且也為更好地解決帶內(nèi)環(huán)向加強(qiáng)筋薄壁類殼體零件的旋壓成形問題提供了參考。
[Abstract]:With inner ring bar and thin wall is a structural form widely used for curved busbar shaped parts. It is the first choice to reduce the weight of the parts under the condition of ensuring the rigidity of the parts and the strength is not reduced. This subject takes the aluminum alloy shell as the research object, and studies the internal spinning forming of the thin-walled shell parts with inner ring stiffeners, through the finite element numerical simulation and test. In this study, the microstructure and properties of two internal spinning processes and products were studied, respectively. The ABAQUS software was used to simulate the two internal spinning processes of the small end spin and the large end spin forming, and the rotating pressure and deformation were calculated and analyzed. The rotary pre forming and final forming spinning process can obtain uniform cylindrical thin-walled parts. The radial pressure of the spinning process is the largest, the axial rotation pressure is the second, the tangential spin pressure is the smallest. Compared with the radial rotation pressure, the tangential spin pressure can be ignored. The spinning of the rear end frame and the middle section of the middle section of the large end of the shell is formed. In the process, the rotating pressure has the platform area and the forming process is stable. In the spinning process of the front frame part of the small end of the shell, the larger the axial stroke of the rotary wheel, the greater the thinning rate, the greater the rotation pressure, the maximum rotation pressure of the shell spinning forming in this process. If the large end is fixed, the enlargement spinning can be realized, but the skin of the shell is covered by the skin. The deformation instability zone appears in the transition region of the front end frame. Through the two spinning process tests on the small end spin and the large end spinning of a thin wall shell of a inner ring, the forming rules of the two internal spinning processes of the large end and the small end spin are respectively studied. There are two processes as follows: when the large end and the small end spin process is used to form a thin-walled shell of the curved busbar, the following two kinds of processes are present: One is that the wall thickness is basically the same while the enlargement is realized; two is the thickness reduction of the wall thickness at the same time when the diameter is expanded. When the large end is whirling, the thinning law of the wall thickness should conform to the sine law when the half cone angle is less than the semi cone angle of the blank, and the thinning law of the wall thickness of the small end whirling is not restricted by the sine law. The internal rotation determined according to the orthogonal test results. The process parameters of pressing forming are as follows: feed ratio 0.6mm/r, thinning rate 25%, rotary wheel corner radius 6mm, rotary wheel installation angle 25 degrees. The small end spinning process of inner ring stiffened thin-walled shell with inner ring reinforced by spinning test is: blank blanking, blank processing, annealing treatment, pre forming, quenching, final forming and parts processing. The art parameters are the maximum thinning rate of pre forming wall thickness 25%, the maximum thinning rate of final forming 10%, rotary wheel corner radius 6mm, rotary wheel feed ratio 0.6mm/r, the wall thickness difference of 50r/min. test parts of spindle speed is + 0.05mm, and the roundness is 0.15mm. to test the microstructure and mechanical properties of a thin-walled shell spinning test piece. The test results show that the grain of the products formed by the annealing spinning process is relatively small, the size is between 1 m~5 and m, but the strength is not satisfied with the design requirements, while the grain size of the pre forming end forming combined with the intermediate quenching process is larger and the size is between 15 Mu m~20 mu m, the greater the total deformation, the smaller the grain size and the tensile strength to meet 360MPa. All the testing parts of the internal spinning are produced in the tangential direction, the greater the total deformation is, the greater the amount of the total deformation, the more obvious the tangential fibers are. The residual stress of the products formed by the annealing spinning process is smaller, the residual stress value of the pre forming end forming combined with the intermediate quenching process is relatively large, and the residual stresses of the spinning products are all The finite element numerical simulation and experimental study on the spinning process in the inner ring stiffener shell not only provide the basis for determining the spinning process of a thin-walled shell of an aluminum alloy and realizing the mass production, but also provide a reference for the better solution of the spinning forming of the thin-walled shell parts with inner ring stiffeners.
【學(xué)位授予單位】：燕山大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG306;TG146.21

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