TC4板材局部自阻电加热数控渐进成形的研究
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摘要
钛及钛合金具有优良的性能,在航空航天等部门得到广泛使用,目前应用数量最多的钛合金是TC4。现有的钛合金热加工制造方法工艺复杂,加工费用昂贵,延长了制作周期。而金属板材单点数控渐进成形技术是一种先进的无模成形技术,能够适应产品的多品种、少批量生产。
为了实现TC4钛合金等难成形板料的数控渐进成形,本文首次提出难成形板料局部自阻电加热数控渐进成形技术,并构建了一套实验装置,采用理论分析、数值分析和实验研究相结合的研究方法,对成形机理、工艺数值分析、成形实验、摩擦磨损机理、摩擦和润滑等方面展开了研究,为这项技术的实际应用提供了理论和工艺依据。主要研究内容和学术贡献如下:
(1)研究了成形机理。局部自阻电加热渐进成形是一种剪切变形,厚度变化遵循余弦定理。加工侧板料能够形成综合性能良好的网篮组织。通过分析成形原理,找到了研究的关键因素为电加热原理、热传递和高温塑性成形,并找到了相应的材料和工艺因素。
(2)采用非线性有限元分析软件Marc对TC4钛板局部自阻电加热渐进成形进行数值分析,提出了模拟方法和过程,分析了加工中电压和电流的分布,各种工艺因素对温度场、工具头受力、板料应力和应变的影响规律。根据板料受力状态,把加工区域分为三个部分:弯曲变形,均匀剪切成形,反向弯曲成形。综合考虑加工中应力、应变、加工效率、成形精度和板料氧化等因素,在加工中应该采用较大的电流、层间距和中等工具头直径。
(3)采用正交试验对数值分析进行了验证,确定了各工艺因素对板料加工温度和成形极限影响的显著性水平排列和影响规律。结论表明,电流和进给速度是最重要的工艺因素。TC4板料未加工侧的最佳成形温度范围为500～600℃。确定了各工艺因素对成形精度的影响规律,针对反向成形小角度零件出现的鼓包问题,提出了正向成形然后反向成形的解决办法。针对钛板的热胀冷缩效应,提出了放大加工模型的办法。分析了工艺因素对零件表面形貌的影响规律,提出采用控制电流在线动态监控温度的方法。成形后材料的硬度得到提高,而抗拉强度降低。合理控制成形温度,并防止板料在空气中的氧化,是提高成形件材料性能的关键因素。
(4)对金属板料渐进成形和局部自阻电加热渐进成形摩擦机理进行了研究,指出可以用黏着摩擦理论描述力学模型。局部自阻电加热数控渐进成形的摩擦是一种混合摩擦,分为黏着干摩擦区和边界摩擦区,提出了摩擦力计算公式,并找到了提高加工中润滑的办法。
(5)通过研究工艺参数对成形中的摩擦和磨损的影响,提出寻找一层厚度适宜的二硫化钼耐高温自润滑层,是提高润滑和TC4板料性能,减少板料氧化和磨损的关键。研究表明,电沉积镍基二硫化钼自润滑涂层是一种理想的润滑方法,并提出了一套工艺过程和最佳工艺参数。
Titanium alloys have been widely used for aerospace applications because of superior mechanical properties, and Ti-6Al-4V is the most commonly used alpha/bata titanium alloy in the world. Low-speed forming techniques, such as superplastic forming, are usually used to process Ti-6Al-4V at present, but complex heat-resistant dies and expensive heating equipment are needed. In recent years, single point incremental forming (SPIF) has emerged as a flexible forming method that allows manufacturing of 3D sculptured sheet metal parts without the need for expensive, dedicated tools, and the process is economical to form complex parts in small to medium batches.
In order to apply the single point incremental forming technique in the forming of Ti-6Al-4V titanium sheet, in the current work, a novel technique named electric hot single point incremental forming (EHSPIF) was proposed to process hard-to-form sheet metals, and a processing system was developed. With the help of theoretical analysis, numerical analysis and experimental study, the research presented in the dissertation includes the forming mechanism, the numerical analysis and optimization of the technology, forming experiment of Ti-6Al-4V titanium sheet, the mechanism of friction and wear, and abrasion and lubrication test. The research provides a theoretical and technical basis for the practical application of this technology. The results and the main contributions of the dissertation are as following.
(1) EHSPIF is a kind of shear deformation, the change of thickness obeys the cosine law, and basketwave microstructure with high performance can be formed on the formed side. By analyzing the forming mechanism, key factors including electric hot, heat transfer and hot plastic deformation were pointed out, and factors of material and processing were also given.
(2) Electric hot incremental forming of Ti-6Al-4V titanium sheet was simulated by using MSC.Marc software, and the simulation method and process were given. The distribution of voltage and current was analysed, and influencing regularities of every factor on temperature fields, force, and stress and strain of sheet metal were also studied. According to force status of sheet, the forming region is divided into three parts: the bending deformation, shear forming, reverse bending forming. In order to aquire a workpiece with high combination property, larger current and step down, middle diameter tool were proposed to adopt.
(3) Orthogonal experiments were designed to verify results of numerical analysis, factors were arranged according to the significance level of impact on temperature field and forming limit, and the influencing regularity of every factor was also given. The results show that the current and feed speed are important technological factors, and the best forming temperature range is 500～600℃. The influencing regularity of every factor on forming accuracy was also studied and given. Surface bulging occured when a small angle workpiece was negative formed, and the solution was given. The influence of each processing factor on the surface topography was studied, and online detection and current control were proposed to control temperature accurately. The material property of the forming workpiece was studied, and methods to improve the property were found.
(4) Friction mechanisms of SPIF and EHSPIF were studied, and the mechanical model can be described by adhesive friction theory. The friction of EHSPIF is a mixed friction, and is divided into adhesive dry friction and boundary friction. The formula for calculating friction was proposed, and the way to improve lubricating effect was found.
(6) Influences of process parameters on friction and wear were investigated, and a molybdenum disulfide self-lubricating coating with appropriate thickness was proposed to improve the lubricating effect and property of forming sheet, at the same time, to decrease the oxidation and wear of sheet metal. The electrolytic codepositon of molybdenum disulfide with nickel was proposed as an ideal lubrication used in EHSPI, and a set of processes and optimal parameters were suggested.
为了实现TC4钛合金等难成形板料的数控渐进成形,本文首次提出难成形板料局部自阻电加热数控渐进成形技术,并构建了一套实验装置,采用理论分析、数值分析和实验研究相结合的研究方法,对成形机理、工艺数值分析、成形实验、摩擦磨损机理、摩擦和润滑等方面展开了研究,为这项技术的实际应用提供了理论和工艺依据。主要研究内容和学术贡献如下:
(1)研究了成形机理。局部自阻电加热渐进成形是一种剪切变形,厚度变化遵循余弦定理。加工侧板料能够形成综合性能良好的网篮组织。通过分析成形原理,找到了研究的关键因素为电加热原理、热传递和高温塑性成形,并找到了相应的材料和工艺因素。
(2)采用非线性有限元分析软件Marc对TC4钛板局部自阻电加热渐进成形进行数值分析,提出了模拟方法和过程,分析了加工中电压和电流的分布,各种工艺因素对温度场、工具头受力、板料应力和应变的影响规律。根据板料受力状态,把加工区域分为三个部分:弯曲变形,均匀剪切成形,反向弯曲成形。综合考虑加工中应力、应变、加工效率、成形精度和板料氧化等因素,在加工中应该采用较大的电流、层间距和中等工具头直径。
(3)采用正交试验对数值分析进行了验证,确定了各工艺因素对板料加工温度和成形极限影响的显著性水平排列和影响规律。结论表明,电流和进给速度是最重要的工艺因素。TC4板料未加工侧的最佳成形温度范围为500～600℃。确定了各工艺因素对成形精度的影响规律,针对反向成形小角度零件出现的鼓包问题,提出了正向成形然后反向成形的解决办法。针对钛板的热胀冷缩效应,提出了放大加工模型的办法。分析了工艺因素对零件表面形貌的影响规律,提出采用控制电流在线动态监控温度的方法。成形后材料的硬度得到提高,而抗拉强度降低。合理控制成形温度,并防止板料在空气中的氧化,是提高成形件材料性能的关键因素。
(4)对金属板料渐进成形和局部自阻电加热渐进成形摩擦机理进行了研究,指出可以用黏着摩擦理论描述力学模型。局部自阻电加热数控渐进成形的摩擦是一种混合摩擦,分为黏着干摩擦区和边界摩擦区,提出了摩擦力计算公式,并找到了提高加工中润滑的办法。
(5)通过研究工艺参数对成形中的摩擦和磨损的影响,提出寻找一层厚度适宜的二硫化钼耐高温自润滑层,是提高润滑和TC4板料性能,减少板料氧化和磨损的关键。研究表明,电沉积镍基二硫化钼自润滑涂层是一种理想的润滑方法,并提出了一套工艺过程和最佳工艺参数。
Titanium alloys have been widely used for aerospace applications because of superior mechanical properties, and Ti-6Al-4V is the most commonly used alpha/bata titanium alloy in the world. Low-speed forming techniques, such as superplastic forming, are usually used to process Ti-6Al-4V at present, but complex heat-resistant dies and expensive heating equipment are needed. In recent years, single point incremental forming (SPIF) has emerged as a flexible forming method that allows manufacturing of 3D sculptured sheet metal parts without the need for expensive, dedicated tools, and the process is economical to form complex parts in small to medium batches.
In order to apply the single point incremental forming technique in the forming of Ti-6Al-4V titanium sheet, in the current work, a novel technique named electric hot single point incremental forming (EHSPIF) was proposed to process hard-to-form sheet metals, and a processing system was developed. With the help of theoretical analysis, numerical analysis and experimental study, the research presented in the dissertation includes the forming mechanism, the numerical analysis and optimization of the technology, forming experiment of Ti-6Al-4V titanium sheet, the mechanism of friction and wear, and abrasion and lubrication test. The research provides a theoretical and technical basis for the practical application of this technology. The results and the main contributions of the dissertation are as following.
(1) EHSPIF is a kind of shear deformation, the change of thickness obeys the cosine law, and basketwave microstructure with high performance can be formed on the formed side. By analyzing the forming mechanism, key factors including electric hot, heat transfer and hot plastic deformation were pointed out, and factors of material and processing were also given.
(2) Electric hot incremental forming of Ti-6Al-4V titanium sheet was simulated by using MSC.Marc software, and the simulation method and process were given. The distribution of voltage and current was analysed, and influencing regularities of every factor on temperature fields, force, and stress and strain of sheet metal were also studied. According to force status of sheet, the forming region is divided into three parts: the bending deformation, shear forming, reverse bending forming. In order to aquire a workpiece with high combination property, larger current and step down, middle diameter tool were proposed to adopt.
(3) Orthogonal experiments were designed to verify results of numerical analysis, factors were arranged according to the significance level of impact on temperature field and forming limit, and the influencing regularity of every factor was also given. The results show that the current and feed speed are important technological factors, and the best forming temperature range is 500～600℃. The influencing regularity of every factor on forming accuracy was also studied and given. Surface bulging occured when a small angle workpiece was negative formed, and the solution was given. The influence of each processing factor on the surface topography was studied, and online detection and current control were proposed to control temperature accurately. The material property of the forming workpiece was studied, and methods to improve the property were found.
(4) Friction mechanisms of SPIF and EHSPIF were studied, and the mechanical model can be described by adhesive friction theory. The friction of EHSPIF is a mixed friction, and is divided into adhesive dry friction and boundary friction. The formula for calculating friction was proposed, and the way to improve lubricating effect was found.
(6) Influences of process parameters on friction and wear were investigated, and a molybdenum disulfide self-lubricating coating with appropriate thickness was proposed to improve the lubricating effect and property of forming sheet, at the same time, to decrease the oxidation and wear of sheet metal. The electrolytic codepositon of molybdenum disulfide with nickel was proposed as an ideal lubrication used in EHSPI, and a set of processes and optimal parameters were suggested.
引文
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