环件轧制过程数值模拟的研究.pdfVIP

摘 要 环件轧制是一种生产无缝环件的特种加工工艺，它是通过局部连续轧制的方 法，将小直径大截面的环形毛坯逐渐碾扩成大直径小截面的环形件。经典理论的研 究只能初略地反映环件轧制工艺过程，传统的试凑法使得产品制造周期长、成本高。 本文首次基于通用有限元软件 Deform 实现了环件轧制三维动态全过程数值仿真模 拟，对一个生产周期内环件轧制动态过程进行了数值模拟研究，并对环件轧制一些 关键性的设计参数进行了优化分析。 本文首先建立了模拟金属体积成形的刚塑性动力显式有限元方程，推导出刚塑 性大变形应力应变本构关系，然后对某平板轧制过程进行了数值模拟，并把仿真结 果与实际数据进行了对比分析，从而验证基于 Deform 软件进行金属塑性成形数值 模拟的可靠性，同时也初步探索了基于此软件模拟金属塑性成形特性，确定关键影 响因素，随后建立了某矩形截面环件虚拟轧制的三维动态仿真模型，对该环件一个 生产周期内生产过程进行动态模拟，实现环件的虚拟轧制，并基于该环件轧制模型， 对环件轧制工艺的一些关键变量进行优化分析，探索影响环件轧制过程和效率的关 键因素，从而达到优化毛坯结构参数和轧制工艺的目的，为实际环件轧制过程提供 参考。最后，基于该环件轧制仿真模型平台，对某台阶异形截面环件进行一个生产 周期内轧制过程进行动态数值模拟，从而把该有限元仿真模型推广到异形截面环件 的虚拟轧制，进一步拓宽该环件轧制仿真方法的应用范围。 通过仿真实验可以看出，应用有限元软件对环件轧制过程进行动态分析，具有 产品设计预见性好、设计周期短、响应市场快、降低成本等显著优点。 关键词：环件轧制;数值模拟;有限元;径轴向轧环机 I ABSTRACT Ring rolling is a special craft for producing seamless rings, which crushes ring blank into bigger diameter and smaller cross section through continuously local rolling. Classical theoretical investigation only describes ring rolling craft coarsely while the traditional trial-and-error method delays periodicity and increases cost. The general finite element software Deform is adopted in this thesis for ring rolling. A three dimensional model is created to simulate the dynamic rolling process within a period time and fatal design factors are analyzed and promoted for ring rolling after the numerical simulation. An explicit finite element equation is employed to determine the rigid-plastic stress and strain constitutive relation for large deformation, and a slab rolling is simulated and then the results are compared subsequently to validate the feasibility of Deform in simulating plastic deformation of metal，meanwhile the deformation characteris