冷滚打成形力及金属变形的有限元数值模拟

中国机械工程

冷滚打成形力及金属变形的有限元数值模拟

李龙;李言;崔莅沐;黄赓;杨明顺

西安理工大学机械与精密仪器工程学院，西安，710048

出版日期:2017-08-25 发布日期:2017-08-24
基金资助:
国家自然科学基金资助项目（51475366，51475146）；
高等学校博士学科点专项科研基金资助项目（20116118110005）；
西安理工大学博士学位论文创新基金资助项目（310-252071601）
National Natural Science Foundation of China （No. 51475366，51475146）
Specialized Research Fund for the Doctoral Program of Higher Education of China （No . 20116118110005）

Finite Element Numerical Simulation of Forming Forces and Metal Deformations in Cold Roll-beating Forming Processes

LI Long;LI Yan;CUI Limu;HUANG Geng;YANG Mingshun

School of Machinery and Precision Instrument Engineering,Xi'an University of Technology,Xi'an，710048

Online:2017-08-25 Published:2017-08-24
Supported by:
National Natural Science Foundation of China （No. 51475366，51475146）
Specialized Research Fund for the Doctoral Program of Higher Education of China （No . 20116118110005）

摘要/Abstract

摘要： 为了得到能够准确高效计算冷滚打成形实体零件外齿形的成形力和整体金属塑性变形情况的数值模拟方法，根据冷滚打成形的基本原理，建立了能够表征冷滚打成形实体零件外齿形特点的典型有限元模型，并参照实验条件进行了实例计算。所得计算结果与实验相比较，证明了该计算模型和方法能够有效反映出稳定成形时主成形力的平均峰值。同时金属塑性变形的计算结果能有效反映冷滚打成形齿形时的金属变形情况，能够预测和解释外沿飞边和纵向的弓形缺陷的发生。在此基础上研究了提高数值计算效率的方法，得出质量缩放因子取60 000、最小单元格长度0.25mm时可获得较高的计算效率。

关键词: 冷滚打, 成形力, 数值模拟, 冷成形

Abstract: To get an accurate and efficient numerical simulation method of forming forces and the overall metal plastic deformations of the external tooth cold roll-beating forming, based upon the basic principles of cold rolling forming, a typical finite element model was established to characterize external tooth cold roll-beating forming, and the example was calculated according to the experimental conditions. The culculation results compared with the experimental ones, it is shown that this calculation model and method may describe the main forming force average peaks in stable forming. Meanwhile the calculation results of metal plastic deformations may effectively reflect tooth formations of cold rolling forming, predict and explain the occurrences of the flashes on the edges and the bow defects. Then, the method was investigated to improve the efficiency of the numerical calculation, the higher computational efficiency may be obtained when the mass scaling factor is as 60 000 and the minimum element length is as 0.25mm.

Key words: cold roll-beating, forming force, numerical simulation, cold forming

中图分类号:

O344

李龙;李言;崔莅沐;黄赓;杨明顺. 冷滚打成形力及金属变形的有限元数值模拟[J]. 中国机械工程.

LI Long;LI Yan;CUI Limu;HUANG Geng;YANG Mingshun. Finite Element Numerical Simulation of Forming Forces and Metal Deformations in Cold Roll-beating Forming Processes[J]. China Mechanical Engineering.

参考文献

[1]TEKKAYA A E, ALLWOOD J M, BARIANI P F, et al. Metal Forming beyond Shaping: Predicting and Setting Product Properties[J]. CIRP Annals—Manufacturing Technology, 2015, 64(2): 629-653.
[2]张璐，李言，杨明顺，等. 增量成形研究进展[J]. 宇航材料工艺, 2011, 41(6): 32-38.
ZHANG Lu, LI Yan, YANG Mingshun. Recent Development of Incremental Forming [J]. Aerospace Materials & Technology, 2011, 41(6): 32-38.
[3]GROB E，KRAPFENBAUER H. Roller Head for Cold Rolling of Splined Shafts or Gears： US, US3818735[P]. 1974-06-25.
[4]马群，李言，杨明顺，等. 连续分度冷滚打机床滚打头结构改进[J]. 兵工学报, 2015, 36(8): 1587-1593.
MA Qun, LI Yan, YANG Mingshun, et al. Structure Improvement of Roll-beating Head for Continuous Indexing Cold Roll-beating Machine [J]. Acta Armamentarii, 2015, 36(8): 1587-1593.
[5]袁启龙，李言，杨明顺，等. 块体材料冷滚打成形变形力研究[J]. 中国机械工程, 2014, 25(2): 251-256.
YUAN Qilong, LI Yan, YANG Mingshun, et al. Research on Deforming Force of Slab Cold Roll-beating [J]. China Mechanical Engineering, 2014, 25(2): 251-256.
[6]KRAPFENBAUER H. New Aspects for the Mass Production of Spur Gears by Cold Rolling[J]. IPE International Industrial＆Production Engineering, 1984, 8(3): 39-4l.
[7]李玉玺，李言，杨明顺，等. 滚珠丝杠冷滚打的齿形理论误差研究[J]. 兵工学报, 2015, 36(8): 1594-1600.
LI Yuxi, LI Yan, YANG Mingshun， et al. Investigation of the Tooth Profile Error Based on the Forming Theory of Balloscrew Manufactured by Cold Rolling [J]. Acta Armamentarii, 2015, 36(8): 1594-1600.
[8]李言，杨明顺，李玢，等. 丝杠冷滚打成形动力学仿真及分析[J]. 西安理工大学学报, 2009, 25(4): 383-387.
LI Yan, YANG Mingshun, LI Fen, et al. Dynamics Simulation and Analysis of Lead Screw Cold Roll-beating[J]. Journal of Xi'an University of Technology, 2009, 25(4): 383-387.
[9]崔凤奎，朱文娟，王晓强，等. 高速冷滚打成形技术研究现状与发展趋势[J]. 河南理工大学学报(自然科学版), 2012, 31(2): 191-200.
CUI Fengkui, ZHU Wenjuan, WANG Xiaoqiang, et al. Current Research and Development Trends of High-speed Cold Rolling Technology [J]. Journal of Henan Polytechnic University(Natural Science), 2012, 31(2): 191-200.
[10]刘相华. 塑性有限元在金属轧制过程中应用的进展[J]. 金属学报, 2010, 46(9): 1025-1033.
LIU Xianghua. Progress and Application of Plastic Finite Element Method in Metals Rolling Process [J]. Acta Metallurgica Sinica, 2010, 46(9): 1025-1033.
[11]ANDRIETTI S，CHENOT J L，BERNACKI M， et al. Recent and Future Developments in Finite Element Metal Forming Simulation[J]. Computer Methods in Materials Science, 2015, 15(2): 265-293.
[12]SAFDARIAN R，NAEINI H M. The Effects of Forming Parameters on the Cold Roll Forming of Channel Section[J]. Thin-Walled Structures, 2015, 92: 130-136.
[13]张洪伟，张以都，吴琼. 喷丸强化过程及冲击效应的数值模拟[J]. 金属学报, 2010, 46(1): 111-117.
ZHANG Hongwei, ZHANG Yidu, WU Qiong. Numerical Simulations of Shot-peening Process and Impact Effect [J]. Acta Metallurgica Sinica, 2010, 46(1): 111-117.
[14]张璐，杨明顺，李言，等. 高速冷滚打过程变形力解析方法及其修正[J]. 塑性工程学报, 2011, 18(5): 1-7.
ZHANG Lu, YANG Mingshun, LI Yan， et al. Analytic Method and Its Modification for Deformation Force of High-speed Cold Roll-beating Forming [J]. Journal of Plasticity Engineering, 2011, 18(5): 1-7.
[15]CUIFengkui，WANG Xiaoqian，ZHANG Fengshou， et al. Metal Flowing of Involute Spline Cold Roll-beating Forming[J]. Chinese Journal of Mechanical Engineering, 2013, 26(5): 1056-1062.