塑性成形中非局部摩擦的数值分析与实验
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摘要
在金属塑性成形加工过程中,模具与工件之间存在着摩擦。摩擦起着重要作用。摩擦模型是求解金属塑性成形力学问题的边界条件之一。目前,只能用简化的摩擦模型代替真实的摩擦分布。常用的简化摩擦模型有:库仑摩擦模型和常摩擦模型。从连续介质力学的观点来考虑,接触界面被视为具有剪切强度的连续膜。在金属塑性成形加工力学中,接触面上逐点采用的库仑摩擦定律是局部性质的,即接触面上摩擦域内某质点的摩擦效应只与该点的状态有关。然而,实际上金属表面往往是粗糙的,接触界面是粗糙面之间的接触,某一点的摩擦效应不仅与该点的状态直接相关,还与该点有限大小邻域内的其它点的状态有关,这是一种非局部摩擦效应。因此,在细观尺度上有必要用非局部摩擦模型替代库仑摩擦模型来考虑接触界面上微凸结构所引起的非局部摩擦效应。
本论文的主要内容有:
采用非局部摩擦模型代替库仑摩擦模型研究了轧制过程中接触面上单位压力分布规律,得出了非局部摩擦下的轧制单位压力计算公式,并分析了不同工况条件下非局部摩擦模型与库仑摩擦模型对接触面上单位压力分布影响的差异。
首次将Oden等提出的非局部摩擦理论应用于冷挤压过程的流体润滑机理分析,建立了一种非局部形式的流体润滑模型,并利用摄动方法求出了其近似解。
基于ADINA中用户子程序进行了摩擦模型的二次开发,将非局部摩擦模型引入ADINA中。
利用有限元数值模拟方法,从宏观和细观方面研究了非局部摩擦模型对塑性成形过程的影响,将非局部摩擦模型用于轴对称圆柱体镦粗工艺中,得到不同压下量与接触法向应力的变化关系,及接触面上压应力和摩擦应力的分布规律。分析了微凸体分布密度不同、微凸体高度不同时,非局部摩擦的影响变化规律。
设计制作了一套摩擦测试实验系统,从实验中得出随着压力的增加、接触面积的增加,摩擦系数减小以及随着压下量的增加,接触面平均压应力的变化规律,并与模拟值进行了比较。
以上研究结果表明,采用非局部摩擦模型代替局部的库仑摩擦模型对塑性成形加工过程的摩擦行为进行分析,虽然增加了问题的复杂性,但使分析的结果更精确、更真实。非局部摩擦模型的采用将有助于我们更加深入地认识金属塑性成形加工过程中的摩擦机理,有益于探索非局部摩擦模型的应用价值、拓展非局部摩擦模型的应用范围,为细微成形加工技术的应用与发展奠定良好的理论基础,为塑性加工工艺和塑性加工技术的改进与创新提供广阔的前景。
Friction exists on the surface between tool and workpiece. It plays important role during metal forming processes. Friction model is one of the boundary conditions for the solution of mechanical problem of metal plastic forming. At present, only simplified friction model can be used to replace the actual friction distribution. Coulomb's friction model and Constant friction model are widely used simplified models. From the perspective of continum mechanics, contact surfaces are perceived as continual smooth surface instead of rough surfaces that are real surfaces of materials in contact. In mental plastic forming processing, the Coulomb friction law applied on each point of the contact surface is local, which means the friction stress at one point in a certain range of contact surface is only affected by normal stress at the same point. However, real metal surfaces are not smooth, and the contact surface is actually contacts between rough surfaces. In this case, the friction stress of a certain point is not only related to the normal stress of this point, but is affected by the other points' normal stress in a neighborhood of the point. This is called the nonlocal friction effect. Therefore, it is necessary to use nonlocal friction model as a replacement of Coulomb's friction model to analyse the nonlocal friction effect caused by the asperity structure on the contact surface on micro-level.
The main content of the research paper is:
Nonlocal friction model is applied as a replacement of Coulomb's friction model to study the distribution of pressure on the contact surface in the rolling process. A formula to caculate the pressure in the rolling process with nonlocal friction is obtained. What's more, the differences between the influences on the distribution of pressure on the contact surface casted by nonlocal friction model and Coulomb's friction model under different conditions is also studied.
The nonlocal friction model theory proposed by Oden is first applied to use in the analysis of lubricating fluid mechanism in the cold extrusion process. A nonlocal lubricating model is established. Perturbation theory is used to get approximate solution.
The friction user subroutine of ADINA has been studied. A new development of friction model is done based on the user subroutine of ADINA. Nonlocal friction model is introduced into ADINA.
The influence of nonlocal friction model on the plastic forming process is studied both on a macro-level and on a micro-level by using initial numerical simulation. By applying the nonlocal friction model to the cylinder upsetting process the changing relations between the different height reduction and contact normal stress is found. The distribution of normal stress and friction stress on contact surfaces is also found. The influence of density distribution and height of the asperities on nonlocal friction is also studied here.
A experimental system for friction test is designed. According the experiment, with the increase of stress and the area of the contact surface, friction coefficient become smaller. The pattern of how average normal stress changes on contact surfaces as the reduction increases is studied and the result is compared with the simulation results.
All the research findings show that although using nonlocal friction model in replacement of Coulomb's friction model to analyse the friction in the plastic forming process has made the problem more complex, the findings of the analysis is more accurate and true. The application of nonlocal friction model is helpful for us to gain a deeper understanding of the friction mechanism in the metal plastic forming process. It is helpful for us to explore the value of the nonlocal friction model and extending the application range of it. It can serve as good theoretical bases for the application and development of the minor forming and processing technology. It can provide a promising future for the improvement and innovation of plastic processing technology.
本论文的主要内容有:
采用非局部摩擦模型代替库仑摩擦模型研究了轧制过程中接触面上单位压力分布规律,得出了非局部摩擦下的轧制单位压力计算公式,并分析了不同工况条件下非局部摩擦模型与库仑摩擦模型对接触面上单位压力分布影响的差异。
首次将Oden等提出的非局部摩擦理论应用于冷挤压过程的流体润滑机理分析,建立了一种非局部形式的流体润滑模型,并利用摄动方法求出了其近似解。
基于ADINA中用户子程序进行了摩擦模型的二次开发,将非局部摩擦模型引入ADINA中。
利用有限元数值模拟方法,从宏观和细观方面研究了非局部摩擦模型对塑性成形过程的影响,将非局部摩擦模型用于轴对称圆柱体镦粗工艺中,得到不同压下量与接触法向应力的变化关系,及接触面上压应力和摩擦应力的分布规律。分析了微凸体分布密度不同、微凸体高度不同时,非局部摩擦的影响变化规律。
设计制作了一套摩擦测试实验系统,从实验中得出随着压力的增加、接触面积的增加,摩擦系数减小以及随着压下量的增加,接触面平均压应力的变化规律,并与模拟值进行了比较。
以上研究结果表明,采用非局部摩擦模型代替局部的库仑摩擦模型对塑性成形加工过程的摩擦行为进行分析,虽然增加了问题的复杂性,但使分析的结果更精确、更真实。非局部摩擦模型的采用将有助于我们更加深入地认识金属塑性成形加工过程中的摩擦机理,有益于探索非局部摩擦模型的应用价值、拓展非局部摩擦模型的应用范围,为细微成形加工技术的应用与发展奠定良好的理论基础,为塑性加工工艺和塑性加工技术的改进与创新提供广阔的前景。
Friction exists on the surface between tool and workpiece. It plays important role during metal forming processes. Friction model is one of the boundary conditions for the solution of mechanical problem of metal plastic forming. At present, only simplified friction model can be used to replace the actual friction distribution. Coulomb's friction model and Constant friction model are widely used simplified models. From the perspective of continum mechanics, contact surfaces are perceived as continual smooth surface instead of rough surfaces that are real surfaces of materials in contact. In mental plastic forming processing, the Coulomb friction law applied on each point of the contact surface is local, which means the friction stress at one point in a certain range of contact surface is only affected by normal stress at the same point. However, real metal surfaces are not smooth, and the contact surface is actually contacts between rough surfaces. In this case, the friction stress of a certain point is not only related to the normal stress of this point, but is affected by the other points' normal stress in a neighborhood of the point. This is called the nonlocal friction effect. Therefore, it is necessary to use nonlocal friction model as a replacement of Coulomb's friction model to analyse the nonlocal friction effect caused by the asperity structure on the contact surface on micro-level.
The main content of the research paper is:
Nonlocal friction model is applied as a replacement of Coulomb's friction model to study the distribution of pressure on the contact surface in the rolling process. A formula to caculate the pressure in the rolling process with nonlocal friction is obtained. What's more, the differences between the influences on the distribution of pressure on the contact surface casted by nonlocal friction model and Coulomb's friction model under different conditions is also studied.
The nonlocal friction model theory proposed by Oden is first applied to use in the analysis of lubricating fluid mechanism in the cold extrusion process. A nonlocal lubricating model is established. Perturbation theory is used to get approximate solution.
The friction user subroutine of ADINA has been studied. A new development of friction model is done based on the user subroutine of ADINA. Nonlocal friction model is introduced into ADINA.
The influence of nonlocal friction model on the plastic forming process is studied both on a macro-level and on a micro-level by using initial numerical simulation. By applying the nonlocal friction model to the cylinder upsetting process the changing relations between the different height reduction and contact normal stress is found. The distribution of normal stress and friction stress on contact surfaces is also found. The influence of density distribution and height of the asperities on nonlocal friction is also studied here.
A experimental system for friction test is designed. According the experiment, with the increase of stress and the area of the contact surface, friction coefficient become smaller. The pattern of how average normal stress changes on contact surfaces as the reduction increases is studied and the result is compared with the simulation results.
All the research findings show that although using nonlocal friction model in replacement of Coulomb's friction model to analyse the friction in the plastic forming process has made the problem more complex, the findings of the analysis is more accurate and true. The application of nonlocal friction model is helpful for us to gain a deeper understanding of the friction mechanism in the metal plastic forming process. It is helpful for us to explore the value of the nonlocal friction model and extending the application range of it. It can serve as good theoretical bases for the application and development of the minor forming and processing technology. It can provide a promising future for the improvement and innovation of plastic processing technology.
引文
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