平面板材表面輥壓成形微溝槽數(shù)值模擬研究
發(fā)布時(shí)間：2018-08-19 07:28
【摘要】：隨著表面微溝槽的功能特性被科學(xué)研究所證實(shí)，其應(yīng)用前景和潛在的使用價(jià)值引起世界廣泛地關(guān)注，因此微溝槽加工技術(shù)也不斷發(fā)展起來(lái)。目前微溝槽加工技術(shù)還難以同時(shí)滿足工業(yè)生產(chǎn)上的大批量、低成本、高質(zhì)量的要求，因此本文提出一種平面板材表面微溝槽輥壓成形技術(shù)。它是利用帶有一定功能特性微溝槽的剛性輥對(duì)板材件進(jìn)行輥壓成形，使得板材表面發(fā)生塑性變形，從而在板材表面得到一定尺寸的微細(xì)溝槽的加工方法。與其它微細(xì)加工技術(shù)相比，該技術(shù)不僅能夠?qū)崿F(xiàn)帶有微溝槽板材件的連續(xù)成形，提高生產(chǎn)效率，而且可以獲得較好的成形質(zhì)量，有利于后續(xù)的二次加工。 本文建立了板材表面微溝槽輥壓成形有限元模型，并對(duì)不同工藝參數(shù)進(jìn)行了數(shù)值模擬分析。通過(guò)對(duì)比分析成形過(guò)程中成形件的應(yīng)力、應(yīng)變分布和微溝槽尺寸，以得到最佳的輥壓成形參數(shù)；并利用輥壓成形實(shí)驗(yàn)裝置，在鋁合金板材表面加工出帶有一定尺寸的微溝槽，驗(yàn)證了該成形方式的可行性。本文得出主要結(jié)論如下： 1.根據(jù)成形過(guò)程中成形力的變化規(guī)律，將成形過(guò)程分為擠壓階段、穩(wěn)定成形階段、結(jié)束階段。在擠壓階段，隨著輥?zhàn)訅喝肷疃鹊脑龃�，成形力隨之增大到最大值；當(dāng)進(jìn)入穩(wěn)定成形階段，成形力在最大值附近穩(wěn)態(tài)波動(dòng)；在輥壓結(jié)束階段，隨著輥?zhàn)优c板材接觸面積減小，成形力逐漸減小，直至板材脫離輥縫。根據(jù)板材變形后等效應(yīng)變分布可知，板溝槽底部的應(yīng)變值相對(duì)于溝槽側(cè)壁處較大。沿板材輥壓縱向?qū)Ρ劝宀娜肟诙恕⒅虚g端、出口端的金屬流入輥?zhàn)影疾鄣母叨?微溝槽填充高度)，結(jié)果表明：在板材出口端和入口端處，表面溝槽成形高度小于板材中間部分。 2.研究分析45°底角的等腰梯形、60°底角的等腰梯形、正弦波紋、等邊三角形四種結(jié)構(gòu)微溝槽在不同壓下量下的成形結(jié)果。結(jié)果表明：45°底角的等腰梯形溝槽、60°底角的等腰梯形溝槽和正弦曲線溝槽在材料填滿時(shí)，所需的壓下量分別為0.7mm、0.75mm、0.83mm；而等邊三角形溝槽在壓下量為0.9mm時(shí)，溝槽僅基本接近目標(biāo)形狀，在三角形頂邊處仍未填滿。 3.分析了板材寬展和板材厚度對(duì)成形結(jié)果的影響。當(dāng)約束板材寬展時(shí)，板材的縱向延展大，，并且具有一致性；當(dāng)板材自由寬展時(shí)，板材表面溝槽成形高度相對(duì)較小，且成形均勻性較差。隨著厚度的減薄，表面溝槽填充高度相對(duì)增大。 4.論文對(duì)比分析了壓下量、摩擦系數(shù)、輥?zhàn)愚D(zhuǎn)速三種參數(shù)對(duì)表面微溝槽成形結(jié)果的影響。結(jié)果表明：隨著壓下量增大，板材表面微溝槽成形高度呈線性增長(zhǎng)。當(dāng)摩擦系數(shù)較大時(shí)，輥壓微溝槽的成形力較大，微溝槽成形高度減小。當(dāng)上、下兩輥轉(zhuǎn)速相同時(shí)，隨著輥?zhàn)愚D(zhuǎn)速的增大，板材表面微溝槽成形高度減�。划�(dāng)上、下兩輥具有一定的轉(zhuǎn)速差時(shí)，隨著差值的增大，溝槽成形高度增大。
[Abstract]:As the functional characteristics of surface microgrooves have been confirmed by scientific research, their application prospects and potential use value have attracted worldwide attention, so micro-grooves processing technology has been continuously developed. At present, it is difficult to meet the requirements of large quantity, low cost and high quality in industrial production. It is a kind of machining method that the rigid roll with certain function characteristic micro-grooves is used to roll forming the sheet metal, which makes the sheet surface plastic deformation, and then obtains a certain size micro-groove on the plate surface. Compared with other micro-machining techniques, this technology can not only realize continuous forming with micro-grooves, improve production efficiency, but also obtain better forming quality, which is conducive to subsequent secondary processing. In this paper, the finite element model of sheet metal surface micro-groove roll forming is established, and the different process parameters are numerically simulated and analyzed. By comparing and analyzing the stress, strain distribution and microgroove size of the forming parts, the optimum roll forming parameters are obtained, and the micro-grooves with certain size are machined on the surface of aluminum alloy sheet by using the roller forming experimental device. The feasibility of the forming method is verified. The main conclusions are as follows: 1. According to the changing law of forming force in forming process, the forming process is divided into extrusion stage, stable forming stage and end stage. In the extrusion stage, the forming force increases to the maximum with the increase of the roller indentation depth; when it enters the stable forming stage, the forming force fluctuates in the vicinity of the maximum value; at the end of the roll pressing, the contact area between the roller and the sheet metal decreases, The forming force gradually decreases until the sheet is separated from the roll gap. According to the equivalent strain distribution of the plate after deformation, the strain value at the bottom of the plate groove is larger than that at the side wall of the groove. The height of the metal flowing into the roller groove (the filling height of the micro-groove) at the inlet end, the middle end, and the outlet end of the plate is compared along the plate roll press. The results show that: at the exit end and the inlet end of the sheet metal, Surface groove forming height less than the middle part of sheet. 2. The forming results of four microgrooves with isosceles trapezoids, sinusoidal ripples and equilateral triangles with isosceles trapezoids of 45 擄and 60 擄bottom angles of 60 擄are studied. The results show that the isosceles trapezoidal grooves at the bottom angle of 45 擄and the isosceles trapezoidal grooves and sinusoidal grooves at 60 擄bottom angles require a reduction of 0.7 mm / 0.75 mm / 0.83 mm respectively when the material is filled, while the equilateral triangular grooves are reduced by 0.9mm. The grooves are only close to the target shape and are still unfilled at the top of the triangle. The influence of sheet width and sheet thickness on forming results is analyzed. The longitudinal extension of the plate is large and consistent when the plate is restrained, and the forming height of the surface grooves is relatively small and the forming uniformity is poor when the sheet is freely expanded. As the thickness decreases, the surface groove filling height increases relatively. 4. 4. The effects of three parameters, such as reduction, friction coefficient and roll speed, on the forming results of surface grooves are compared and analyzed in this paper. The results show that the forming height of the micro-grooves on the surface increases linearly with the increase of the reduction. When the friction coefficient is high, the forming force and height of the micro-grooves are larger and the forming height of the micro-grooves decreases. When the rotation speed of the next two rollers is the same, the forming height of the micro-grooves on the surface of the plate decreases with the increase of the rotational speed of the roller, and the forming height of the grooves increases with the increase of the difference between the two rollers when the next two rollers have a certain rotational speed difference.
【學(xué)位授予單位】：吉林大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG306
本文編號(hào)：2191073
[Abstract]:As the functional characteristics of surface microgrooves have been confirmed by scientific research, their application prospects and potential use value have attracted worldwide attention, so micro-grooves processing technology has been continuously developed. At present, it is difficult to meet the requirements of large quantity, low cost and high quality in industrial production. It is a kind of machining method that the rigid roll with certain function characteristic micro-grooves is used to roll forming the sheet metal, which makes the sheet surface plastic deformation, and then obtains a certain size micro-groove on the plate surface. Compared with other micro-machining techniques, this technology can not only realize continuous forming with micro-grooves, improve production efficiency, but also obtain better forming quality, which is conducive to subsequent secondary processing. In this paper, the finite element model of sheet metal surface micro-groove roll forming is established, and the different process parameters are numerically simulated and analyzed. By comparing and analyzing the stress, strain distribution and microgroove size of the forming parts, the optimum roll forming parameters are obtained, and the micro-grooves with certain size are machined on the surface of aluminum alloy sheet by using the roller forming experimental device. The feasibility of the forming method is verified. The main conclusions are as follows: 1. According to the changing law of forming force in forming process, the forming process is divided into extrusion stage, stable forming stage and end stage. In the extrusion stage, the forming force increases to the maximum with the increase of the roller indentation depth; when it enters the stable forming stage, the forming force fluctuates in the vicinity of the maximum value; at the end of the roll pressing, the contact area between the roller and the sheet metal decreases, The forming force gradually decreases until the sheet is separated from the roll gap. According to the equivalent strain distribution of the plate after deformation, the strain value at the bottom of the plate groove is larger than that at the side wall of the groove. The height of the metal flowing into the roller groove (the filling height of the micro-groove) at the inlet end, the middle end, and the outlet end of the plate is compared along the plate roll press. The results show that: at the exit end and the inlet end of the sheet metal, Surface groove forming height less than the middle part of sheet. 2. The forming results of four microgrooves with isosceles trapezoids, sinusoidal ripples and equilateral triangles with isosceles trapezoids of 45 擄and 60 擄bottom angles of 60 擄are studied. The results show that the isosceles trapezoidal grooves at the bottom angle of 45 擄and the isosceles trapezoidal grooves and sinusoidal grooves at 60 擄bottom angles require a reduction of 0.7 mm / 0.75 mm / 0.83 mm respectively when the material is filled, while the equilateral triangular grooves are reduced by 0.9mm. The grooves are only close to the target shape and are still unfilled at the top of the triangle. The influence of sheet width and sheet thickness on forming results is analyzed. The longitudinal extension of the plate is large and consistent when the plate is restrained, and the forming height of the surface grooves is relatively small and the forming uniformity is poor when the sheet is freely expanded. As the thickness decreases, the surface groove filling height increases relatively. 4. 4. The effects of three parameters, such as reduction, friction coefficient and roll speed, on the forming results of surface grooves are compared and analyzed in this paper. The results show that the forming height of the micro-grooves on the surface increases linearly with the increase of the reduction. When the friction coefficient is high, the forming force and height of the micro-grooves are larger and the forming height of the micro-grooves decreases. When the rotation speed of the next two rollers is the same, the forming height of the micro-grooves on the surface of the plate decreases with the increase of the rotational speed of the roller, and the forming height of the grooves increases with the increase of the difference between the two rollers when the next two rollers have a certain rotational speed difference.
【學(xué)位授予單位】：吉林大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TG306
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