冷滚打成形中打入量对残余应力的影响规律仿真研究
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摘要
在冷滚打成形过程中,当外加载荷逐渐卸去后成形件内部会出现残余应力,为了有效的控制其对成形件精度的影响,现针对打入量与残余应力之间的关系进行研究。依据冷滚打成形的基本原理,应用Abaqus软件建立了有限元动态仿真模型,通过仿真获得了不同打入量时工件表面Mises力的分布。由于动态仿真结果工件内部的力处于不平衡状态,不能直接进行残余应力求解,所以在动态仿真结果上建立了静态仿真模型,通过静态求解获得在不同打入量下成形工件在切向、轴向和径向的残余应力的变化规律。在自行开发的冷滚打设备上进行试验,运用X射线应力分析仪测量滚打后工件残余应力分布,进行冷滚打成形件残余应力的实验研究。通过对试件测量得到在不同打入量下制件沿深度方向的切向残余应力的分布,试验结果与有限元仿真结果对比分析表明,残余应力变化规律具有很好的一致性。
When the load to be lifted after cold roll-beating forming the residual stress will appear, in order to effectively control its impact on the forming precision, now the relationship between roll-beating depth and the residual stresses were studied. According to basic principle of cold roll-beating, a finite element dynamic simulation model is established by ABAQUS software, the distribution of Mises force on the workpiece surface was obtained by dynamic simulation at different roll-beating depth. Because inner force of workpiece in result of dynamic simulation is at unbalance state, it cannot directly solve the residual stress, so the static simulation model is established on result of dynamic simulation, and the roll-beating depth of different roll-beating of forming gullet section residual stress in tangential direction, axial direction and radial direction is determined by static analysis. Experiment on self-developed cold roll-beating equipment, build experimental platform for residual stress measurement, and study on residual stress of cold roll-beating. The distribution of the tangential residual stress along the depth direction is obtained by the measurement of the workpiece under different roll-beating depth, the comparison between the experimental results and the finite element simulation results shows that the residual stress variation has a good consistency, which verified effectiveness correctly of the simulation model.
When the load to be lifted after cold roll-beating forming the residual stress will appear, in order to effectively control its impact on the forming precision, now the relationship between roll-beating depth and the residual stresses were studied. According to basic principle of cold roll-beating, a finite element dynamic simulation model is established by ABAQUS software, the distribution of Mises force on the workpiece surface was obtained by dynamic simulation at different roll-beating depth. Because inner force of workpiece in result of dynamic simulation is at unbalance state, it cannot directly solve the residual stress, so the static simulation model is established on result of dynamic simulation, and the roll-beating depth of different roll-beating of forming gullet section residual stress in tangential direction, axial direction and radial direction is determined by static analysis. Experiment on self-developed cold roll-beating equipment, build experimental platform for residual stress measurement, and study on residual stress of cold roll-beating. The distribution of the tangential residual stress along the depth direction is obtained by the measurement of the workpiece under different roll-beating depth, the comparison between the experimental results and the finite element simulation results shows that the residual stress variation has a good consistency, which verified effectiveness correctly of the simulation model.
引文
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[15] 孙雅洲,刘海涛,卢泽生.基于热力耦合模型的切削加工残余应力的模拟及试验研究 [J].机械工程学报,2011(1):187-193.SUN YaZhou,LIU HaiTao,LU ZeSheng.Finite element simulation and experimental research of residual stresses in the cutting based on the coupled thermo-mechanical model[J].Journal of Mechanical Engineering,2011(1):187-193(In Chinese).
[2] 许言午,杨鹤群.广义成形技术的发展、应用和未来合作[J].塑性工程学报,2002,9(4):15-19.XU YanWu,YANG HeQun.The development,application and future cooperation of generalized forming technology[J].Journal of Plasticity Engineering,2002,9(4):15-19(In Chinese).
[3] 杨合,孙志超,詹梅.局部加载控制不均匀变形与精密塑性成形进展[J].塑性工程学报,2008,15(2):6-14.YANG He,SUN ZhiChao ZHAN Mei,et al.Advances in control of unequal deformation by locally loading and theories related to precision plastic forming[J].Journal of Plasticity Engineering,2008,15(2):6-14(In Chinese).
[4] 张璐,李言,杨明顺,等.丝杠冷滚打成形过程金属流动规律研究[J].中国机械工程,2012,23(13):1623-1628.ZHANG Lu,LI Yan,YANG MingShun,et al.Study on metal flowing of lead Cold roll-beating forming[J].China Mechanical Engineering,2012,23(13):1623-1628(In Chinese).
[5] 张丰收,冯振,崔凤奎.高速冷滚打成形残余应力研究[J].矿山机械,2014,42(6)111-115.ZHANG FengShou,FENG Zhen,CUI FengKui.Study on residual stress generated during high-speed cold-rolling beat[J].Mining & Processing Equipment,2014,42(6)111-115(In Chinese).
[6] Liu M,Takagi J I.Tsukuda.Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel [J].Journal of Materials Processing Technology,2004,150(3):234-241.
[7] HUA Jiang,Umbrello D,Shivpuri R.Investigation of cutting conditions and cutting edge preparations for enhanced compressive subsurface residual stress in the hard turning of bearing steel [J].Journal of Materials Processing Technology,2006,171(2):180-187.
[8] 吴建强,陈树峰.机械加工表面的残余应力研究[J].煤矿机械,2007,28(8):101-103.WU JianQiang,CHEN ShuFeng.Discussion of surface remaining stress in machinery processing[J].Coal Mine Machinery,2007,28(8):101-103(In Chinese).
[9] 全建辉,崔凤奎.基于ANSYS/LS-DYNA的花键冷滚轧成形数值模拟 [J].中国机械工程,2008,19(4):419-422.QUAN JianHui,CUI FengKui,YANG JianXi,et al.Numerical simulation of Involute spline shaft′ s Cold-rolling forming based on ANSYS/LS-DYNA[J].China Mechanical Engineering,2008,19(4):419-422(In Chinese).
[10] Finn M J,Galbraith P C,Wu L,et al.Use of a coupled explicit-implicit Solver for calculation springback in automotive body panels[J].Journal of Materials Processing Technology,1995,50:395-409[11] Yang D Y,D.Jung W,Song I S,et al.Comparative investigation into implicit,explicit and iterative implicit/explicit schemes for the simulation of sheet-metal forming processes[J].Journal of Materials Processing Technology,1995,50:39-53.
[12] 孙娟,徐永福,胡向军,等.冷滚打花键动力学分析与仿真[J].机械设计与制造,2009(4):196-198.SUN Juan,XU YongFu,HU XiangJun,et al.Dynamics analysis and simulated of cold rolling spline[J].Machinery Design & Manufacture,2009(4):196-198(In Chinese).
[13] 张勇,李鹏阳,王权岱,等.基于Abaqus的单点增量成形的数值分析[J].机械强度,2015,37(1):99-103.ZHANG Yong,LI PengYang,WANG QuanDai,et al.Based on ABAQUS single point increment forming numerical analysis[J].Journal of Mechanical Strength,2015,37(1):99-103(In Chinese).
[14] 杨明顺,李言,袁启龙,等.板料冷滚打成形鳞纹影响因素解析及试验研究[J].机械科学与技术,2013,9(32):1363-1367.YANG MingShun,LI Yan,YUAN QiLong,et al.Theoretical analysis and experimental study on stripe of slab cold roll-beating[J].Mechanical Science and Technology for Aerospace Engineering,2013,9(32):1363-1367(In Chinese).
[15] 孙雅洲,刘海涛,卢泽生.基于热力耦合模型的切削加工残余应力的模拟及试验研究 [J].机械工程学报,2011(1):187-193.SUN YaZhou,LIU HaiTao,LU ZeSheng.Finite element simulation and experimental research of residual stresses in the cutting based on the coupled thermo-mechanical model[J].Journal of Mechanical Engineering,2011(1):187-193(In Chinese).