大挤压比薄壁件复合挤压成形工艺过程的数值模拟

采用等温复合挤压工艺成形大挤压比薄壁件,并应用DEFORM对大挤压比薄壁件的复合挤压过程进行有限元数值模拟,分析成形过程中的变形力及金属流动规律.根据模拟得到的应力场、应变场、速度场及加载变化等,也可预测大挤压比薄壁件复合挤压变形时产生的缺陷.     

非对称挤压研究

提出了挤压中心的新概念,建立了非对称挤压的分析模型和变形理论。通过自行开发的非对称挤压CAD/CAM系统,模拟了变形区的速度场、应变速率场以及摩擦因子、断面减缩率对相对应力的影响,给出了最佳的凹模长度和模面形状等优化参数。     

分流焊合模成形管材过程的数值模拟研究

采用FEM方法对分流焊合模成形管材的挤压变形过程进行了三维模拟,给出了管材挤压过程中铝合金的应力、应变及流动速度等的分布和变化。     

上限元法在模拟杯-杆型复合挤压全过程中的应用

此文采用上限单元法(UBET)模拟了杯-杆型复合挤压的不同变形程度组合(ε_∫/ε_b)对挤压力及两端流出量的影响,并与实验结果进行了比较,实验结果与计算结果相符很好,改善了以往的模拟结果,讨论并分析了提高上限单元法的计算精度的方法。     

冲击载荷下螺栓预紧力对应力波影响分析

目的 研究拉伸冲击载荷作用下螺栓预紧力对应力波的影响.方法 针对螺栓弹性变形、塑性变形和冲击破坏3种情形,对螺栓未施加预紧力及施加不同预紧力下的连接结构进行冲击数值模拟,对比分析连接结构的测点应变及螺栓响应,并与霍普金森拉伸实验结果进行对比.结果 螺栓达到断裂或塑性变形时,预紧力对测点应变及螺栓最大应力影响较小;螺栓弹性变形时,预紧力对测点应变及螺栓最大应力影响较大.结论 螺栓达到断裂或塑性变形时,螺栓拉伸变形远大于预紧力变形,此时预紧力影响可忽略;螺栓在弹性变形时,螺栓拉伸变形与预紧力变形程度接近,此时预紧力影响不可忽略,且预紧力越高,螺栓变形越大.     

两出口环形件的冷挤压成形工艺研究

针对两出口环形件的形状特点,确定了冷挤压成形的方案,设计了零件挤压成形图,校核了挤压工序的变形程度。采用等应变分配原理,得出了分流层直径的大小,并进行了成形力和坯料尺寸的计算。冷挤压成形试验表明,采用冷挤压工艺确保零件的尺寸精度,实现了空调压缩机罩体零件的工程化批量生产,创造了可观的经济效益。     

矩形截面毛坯挤压矩形工件的上限研究

应用上限法建立了由矩形毛坯正挤压矩形截面工件的等挤压比流动模型 ,推导出了三次多项式表示的流线方程 ,给出了变形区的动可容速度场、应变速率场及上限功率的表达式 ,获得了挤压力的上限数值解 ;分析了变形程度、工件截面形状等参数对挤压力的影响 ,并获得了相对挤压应力与截面形状系数之间的近似关系式。研究证明采用流线速度场进行上限分析比其他方法更符合实际情况 ,根据流线设计的凹模优于常规凹模 ,如平底模。     

轴对称两出口轴向挤压金属流动规律的研究

本文在实验的基础上,通过分析比较,提出了塑性变形材料的“等应变分配原理”,并通过对轴对称两出口轴向挤压金属流动规律的研究,对这一原理进行了验证。同时也赋予了平面应变复合挤压分流层几何确定的物理意义。     

240活塞铝裙等温挤压工艺条件的选用及特点

介绍了变形温度、应变速率、润滑剂的使用对LDll等温挤压的影响,在240活塞铝裙等温挤压生产中对上述工艺参数进行了选用及控制;同时就该件等温挤压工艺的特点与热模锻工艺进行了初步比较.     

流函数法在确定上限流动模式中的应用

1967年E.R.Lambert和S.Kobayashi等人对稳定状态成形过程引用了流函数法来确定上限流动模式。这种方法可用之于平面应变问题,也可处理轴对称流动问题。Lambert首先对平面应变状态的挤压过程进行了动可容速度场的研究。以后C.T.Chen与F.F.Ling用流函数法研究了金属经过曲线轮廓凹模的棒料挤压问题,V.Nagpal对通过任何轮廓凹模的平面应变挤压过程进行过分析。他们对不可压缩材料用估计的流线形状来选择动可容速度场族,要求动可容场要满足流线的预定形状以求得与真实变形模型接近一致。本文以通过余弦曲线轮廓凹模的平面应变挤压为例,阐述流函数法在上限流动模式中的应用。     

管材挤压工艺分析及实验研究

对管材挤压成形进行了工艺分析及实验研究。确定了镁合金、70 75铝合金、高温合金等几种材料管材挤压成形工艺参数 ,分析了管材挤压成形时变形力的变化规律。研究结果表明 ,管材挤压成形时必须严格控制坯料温度、模具预热温度、润滑方式、挤压速度、挤压比等工艺技术参数。以上工艺参数对挤压力均有不同程度的影响。     

Simulations of isothermal ECAE for magnesium alloy using FEM software and experimental validations

It is important to research the effect of die structures parameters for equal channel angular extrusion (ECAE) on the deformation behavior, strain distribution and loads requirement. ECAE is an extrusion process widely researched for its potential to produce ultra-fine grained microstructures in magnesium alloys. In this paper some three-dimensional (3D) geometric models with different corner angles 90° and 135° and with fillets or not in the bottom die were designed by UG software. Some important isothermal process parameters were regarded as basal conditions used in DEFORM?-3D software such as temperatures, the friction coefficient, and extrusion speed. The deformation heterogeneity of ECAE was analyzed from the simulation and experimental results. The deformation homogeneity caused by the EACE die with fillets was improved comparing with the die without fillets. But the cumulative maximum strains decreased. The requirement extrusion force decreased with the fillets and channel angle increase in ECAE die. From the simulation and experimental results the smaller channel angle can obtain the higher cumulative strains and produce tinier subgrains. The loads of top die decrease mainly with fillets. The ECAE die with the channel angle 90° and fillets is good to improve the plasticity and deformation homogeneity of the billets if the extrusion force is enough. It was demonstrated that the simulation results were in good agreement with experimental results and the theoretical calculation.     

冷挤压工艺智能设计中的压力计算

冷挤压力的高低是冷挤压工艺成败的关键 ,通常挤压力计算是人工完成的。文中介绍了冷挤压工艺计算机智能设计系统中的挤压力计算及其参数优化部分的软件开发方法。该方法分别介绍了数据库设计、用户界面设计、挤压力计算、工艺评价等内容     

黑色金属挤压力的智能化计算

以MATLAB应用软件作为开发平台介绍了黑色金属挤压力智能化计算软件的开发方法,设计的界面友好,操作简单,可实现冷挤压力的智能化计算以及工艺参数优化设计。软件计算的挤压力的大小与传统方法比较相对误差小于5%。     

Hot extrusion process modeling using a coupled upper bound-finite element method

A thermo-mechanical model has been developed for modeling of hot extrusion processes. Accordingly, an admissible velocity field was first proposed by means of stream function method and then, extrusion pressure as well as temperature variations within the metal and the die were predicted employing a combined upper bound and Petrov–Galerkin finite element analysis. In order to evaluate the model predictions, hot extrusion of AA6061-10%SiC_p was considered under both isothermal and non-isothermal conditions and the predicted force–displacement diagrams under various extrusion conditions were compared with the experimental ones and reasonable consistency was found between the two sets of results.     

AZ31变形镁合金挤压成形工艺的研究

选择AZ31变形镁合金,设计了实心棒材、矩形和圆形截面薄壁空心型材试样,对坯料加热、模具预热、润滑剂、挤压比、挤压速度及挤压力等工艺问题与工艺参数,进行了系统的试验研究,总结了成形规律和确定工艺参数的方法,对生产应用将起到重要的参考作用。     

A three-dimensional finite element simulation of the warm extrusion of AZ31 alloy billets

Extrusion of magnesium billets is associated with large deformations, high strain rates and high temperatures, which results in computationally challenging problems in process simulation. A series of experiments were done to obtain the simulation parameters: stress–strain curves, friction factors and heat transfer coefficient etc. Three-dimensional, thermo-mechanically coupled finite element simulations of extruding a wrought magnesium alloy AZ31 into a small bar at certain ram speeds were performed. The computed model was rotational symmetric and built up by meshing. Computed parameters including workpiece material characteristics and process conditions (billet temperature, reduction ratio, and ram speed) were taken into consideration. The distributions of temperature were different comparing the transient-state extrusion with steady-state extrusion. The extrusion simulation was the reliable predictions of strain rate, effective strains, effective stresses and metal flow velocity in an AZ31 billet during direct extrusion.