基于数值模拟的铝合金薄壁管拉拔工艺优化
Drawing Process Optimization of Thin-walled Aluminum Tube Based on Numerical Simulation
摘 要
使用LS-DYNA有限元软件，建立了铝合金薄壁管拉拔加工的仿真模型，对管材拉拔过程中表面质量降低、壁厚不均以及材料失效等问题进行了原因分析；采用形状与尺寸优化相结合的方式改进了拉拔工艺并进行了试验验证。结果表明：铝合金薄壁管在拉拔过程中，与模具发生非均匀接触，沿拉拔方向材料的流动速度不一致，导致成型后的成品表面出现U形纹路，并诱发棱边开裂失效；通过优化第三道次坯料及模具工作带的形状和尺寸，显著提高了拉拔加工过程中金属流动的均匀性，改善了应变集中问题，并获得了高质量产品。
拉拔
多道次
铝合金薄壁管
finite element method
drawing
multi-pass
thin-walled aluminum tube
Abstract
By using finite element simulation software LS-DYNA, the model for simulating the drawing process of thin-walled aluminum tube was established and the reason of rough surface, non-uniform thickness and material failure in the multi-pass drawing process were analyzed. The drawing process was improved by the combination of shape and size optimization method and verified by experiments. The results show that the contact force between material and die wall was non-uniform during the drawing process of thin-walled aluminum tube, and then the flow rate of metal along the drawing direction was inhomogeneous, which led to U-shaped lines on tube surface and edge failure. With shape and size optimization of blank and die bearing in the 3rd-pass drawing process, the homogeneity of metal flow rate was significant improved, and the strain concentration was eliminated, and then the profile with high quality was fabricated.
中图分类号 TG356.5 DOI 10.11973/jxgccl201512009
所属栏目 物理模拟与数值模拟
基金项目 国家自然科学基金面上资助项目(51475156)；宁夏大学自然科学研究基金资助项目(ZR1403)；宁夏大学人才引进科研启动基金资助项目(BQD2014018)
收稿日期 2015/6/2
修改稿日期 2015/10/23
网络出版日期
作者单位点击查看
备注王冠(1985-)，男，河南郑州人，讲师，博士。
引用该论文: WANG Guan,KOU Lin-yuan,LI Luo-xing. Drawing Process Optimization of Thin-walled Aluminum Tube Based on Numerical Simulation[J]. Materials for mechancial engineering, 2015, 39(12): 35～42
王 冠,寇琳媛,李落星. 基于数值模拟的铝合金薄壁管拉拔工艺优化[J]. 机械工程材料, 2015, 39(12): 35～42
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【4】YOSHIDA K, FURUYA H. Mandrel drawing and plug drawing of shape-memory-alloy fine tubes used in catheters and stents［J］. Journal of Materials Processing Technology, 2004,153/154:145-150.
【5】KIM S W, KWON Y N, LEE Y S, et al. Design of mandrel in tube drawing process for automotive steering input shaft［J］. Journal of Materials Processing Technology, 2007,187/188:182-186.
【6】权国政,周杰.基于仿真技术的圆管空拔成形研究［J］.计算机仿真, 2007,24(5):256-258.
【7】周杰,宋立群,廖旭.高表面质量铝合金矩形管拉拔成形工艺研究［J］.中国机械工程, 2007,18(18):2252-2256.
【8】JOUN M S, HWANG S M. Pass schedule optimal design in multi-pass extrusion and drawing by finite element method［J］. International Journal of Machine Tools and Manufacture, 1993,33(5):713-724.
【9】杨晓静,孙方宏,张志明,等.基于有限元模拟的空拔铜管拉拔参数的优化［J］.有色金属学报, 2008,18(12):2245-2252.
【10】孙小桥,邓长胜.铝合金导线拉拔成型几何模具的优化［J］.科学技术与工程, 2011,11(8):1709-1721.
【11】徐戊矫,王凯庆,朱若岭.铝合金矩形管拉拔成型质量因素分析优化［J］.热加工工艺, 2009,38(23):124-127.
【12】章磊.高精度铝合金矩形管冷拉拔成形中的内表面粗糙度研究［D］.重庆：重庆大学, 2014.
【13】王凯庆.高精度铝合金矩形管多道次冷拉拔成形工艺方案优化及实验验证［D］.重庆：重庆大学, 2012.
【14】MACKENZIE P M, WALKER C A, MCKELVIE J. A method for evaluating the mechanical performance of thin-walled titanium tubes［J］. Thin-Walled Structures, 2007,45(4):400-406.
【15】刘建生,陈慧琴,郭晓霞.金属塑性加工有限元模拟技术与应用［M］.北京:冶金工业出版社, 2003:38-39.
【16】柳艳,李贵茂,殷秋菊,等.拉拔变形程度和电磁搅拌对Cu-6%Ag合金组织及性能的影响［J］.机械工程材料, 2013,37(11):26-30.
【17】CORANA A, MARHESI M, MARTINI C, et al. Minimizing multimodal functions of continuous variables with the simulated annealing algorithm［J］. ACM Transactions on Mathematical Software, 1987,13(3):262-280.
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