CN106971029A - A kind of optimization method based on local loading and shaping gusset part prefabricated blank - Google Patents
A kind of optimization method based on local loading and shaping gusset part prefabricated blank Download PDFInfo
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Abstract
A kind of optimization method based on local loading and shaping gusset part prefabricated blank, by controlling the material of transition region to flow with gross imperfection to realize isothermal local loading and shaping.The prefabricated blank of institute's optimization design of the present invention, can be effectively improved the uniformity of material flowing, reduce the horizontal material in transition region across muscle and flow, improve muscle cavity fill ability.On engineering application, the performance of component is improved, production cost is reduced, to realize that the forming integrated manufacture of titanium alloy large-sized complex component lays the foundation.
Description
Technical field
It is specifically in local loading forming method the present invention relates to the hot-working forging of less-deformable alloy in hot-working field
Under conditions of manufacture gusset part, a kind of optimization method for local loading transition region prefabricated blank shape.
Background technology
Aviation aerospace component increasingly requires large-scale integration, thin-wall light-weighted, complex-shapedization.Using titanium alloy contour
Energy light alloy material and thin-walled, entirety, the lightweight structure with muscle are to improve the Performance And Reliability of parts, realize equipment
Light-weighted effective way.Because titanium alloy resistance of deformation is big, and element structure is complicated, projected area is big, using tradition forging
The such component of technique monolithic molding not only has very high requirement to equipment tonnage, and material filling difficulty, forging easily occurs
The problems such as quality is difficult to ensure that.It is therefore desirable to continue to develop precision plastic forming new principle, new method, research and develop advanced
Plastic forming technology is to realize the figuration manufacture of such large-scale integrated member.Ausforming technology can significantly reduce material flowing should
Power, local loading process not only can effectively reduce forging load, can also expand the size range of formed parts.Isothermal local is loaded
Forming technique organically combines the two, and a new effective way is provided for the figuration manufacture of titanium alloy large-sized overall gusset component
Footpath, can solve the problem that the problem that Aero-Space are manufactured with high-performance light component forming, be advanced in the urgent need to research and development
Plastic forming technology.During local loading and shaping, only to some regional area imposed load of workpiece, then added by conversion
Position, accumulation local deformation are carried, so as to shape whole component.Therefore, loading zone, non-loading zone and connection two are there is on component
The transition region of person.But in forming process, extremely complex inhomogeneous deformation and material flowing can occur for transition region, may
Produce and fold and fill macroscopical forming defects such as discontented.
Gao Pengfei etc. is in The International Journal of Advanced Manufacturing
Technology, volume 76,5-8 phases, the Quantitative analysis of delivered on page 1339-1347 in 2014
the material flow in transitional region during isothermal local loading
Research is found in local loading transition region, forming process in forming of Ti-alloy rib-web component papers
The middle horizontal material transfer existed across muscle, material can be transferred to non-loading zone by loading zone, and this material transfer is to cause transition
Area produces the essential reason of fold defect.Moreover, with the increase of material horizontal transfer amount, the order of severity of folding is linearly closed
System's increase.In addition, Zhang Dawei etc. is in Journal of Materials Processing Technology, the 210th in 2010
Roll up, 2 phases, the Analysis of local loading forming for titanium-alloy delivered on page 258-266
Material of the gusset component during local loading is have studied in T-shaped components using slab method papers
Stream is moved and filling situation, is finished if having been found that and having been filled in the preceding muscle die cavity of upper line journey completion, when upper mould continues pressure, type
Chamber can not accommodate the metal for continuing to fill, and so the metal for forcing filling die cavity is outwards flowed along web, a large amount of metals are caused
It is quick mobile in one direction, it is easily caused adjacent formed rib and produces folding, wears the defects such as muscle, streamline turbulence, and causes
Forging load steeply rises, and reduces die life.If on the contrary, after local loading and shaping terminates, if muscle die cavity is not
It is full of, then can makes muscle up to less than requiring.Because these defects controlling difficulty are larger, seriously constrain isothermal local and load this
Plant the development and application of advanced forming technology.Although above-mentioned paper analyzes material flowing and forming defects from forming technology
Reason, and certain Defects improvements method is proposed according to technological parameters such as friction, drafts, but it does not consider prefabricated blank shape
Influence to forming defects.For complex-shaped gusset part, even if using the technological parameter of optimization, the gross imperfection of transition region
It may not necessarily be completely eliminated, the forming quality of manufactured gusset part there will still likely be some problems.
In addition, in Publication No. CN102632172B, CN102601281A and CN102632173A patent respectively
Give a kind of determination gusset shape three-dimensional structure local loading and shaping not method of blank, determine three-dimensional frame component office
Portion's loading and shaping not method of blank and the method for determining two-dimentional local loading and shaping not blank.It is special at these
In profit, the shape of prefabricated blank uses the not blank of simple form, but its design is only in remote transition region
Overall loading area, the shape positioned at transition region prefabricated blank still uses blank.And be difficult to using blank
The reasonable volume distribution at each position, if the initial volume unreasonable distribution before local loading and shaping, still may in transition region
Cause transition region to produce folding, mould and fill macroscopical forming defects such as discontented.
Transition region is the primary embodiment of local loading and shaping process characteristic, play a part of inhomogeneous deformation coordination, its into
The quality of form quality amount plays very important effect to the military service performance of component., can be effective using rational prefabricated blank shape
The material of control transition region flows and eliminates macroscopical forming defects.Having not yet to see report has in gusset part local loading and shaping
In, positioned at the optimization design of transition region prefabricated blank shape.Because in above-mentioned patent, the shape of prefabricated blank is used simply
Not blank, its structure is the thickness distribution for changing blank different zones by stepped form, can low-cost high-efficiency point
Material volume with each region, reference is provided for the prefabricated blank optimization design in the present invention.
The content of the invention
For overcome prior art in gusset part local loading and shaping transition region there may be fold and muscle mold filling not
Full the problem of, the present invention proposes a kind of optimization method based on local loading and shaping gusset part prefabricated blank.
The present invention detailed process be：
Step 1, transition region geometry is extracted.
Step 2, initial prefabrication base is designed.
Initial prefabrication base uses blank.The projection of shape of blank in the horizontal plane is equal to the throwing of transition region geometry
Shadow area.
Step 3, FEM model is set up.
The FEM model set up includes the geometric shape of assembling die and initial prefabrication base, initial prefabrication base with combining
The temperature for pushing speed and drafts, initial prefabrication base and assembling die of friction factor, upper mould between mould.
The center line of horizontal bar width is the plane of symmetry in described component, and it is imitative to carry out simulation to the plane of symmetry side
Very.
Mould uses assembling die of the prior art, and local loading district location is located at lower mould, the mould under the first piecemeal
Lower surface place backing plate, project upwards mould under the first piecemeal, initial prefabrication base is positioned over mould and the first prominent piecemeal
Between lower mould.
Step 4, local loading and shaping.
The local loading and shaping has two loading steps：
First loading step：Initial prefabrication base is placed in into average rate in heating furnace together with assembling die to be heated to 970 DEG C and protect
Warm 1.5h.When under upper molding, mould is to initial prefabrication base imposed load under the first described piecemeal.After upper line journey terminates, protect
Press 10min.Then, the drift backhaul of forcing press, completes the first loading step.The loading velocity v of the upper mould is 0.2mm/s, just
Friction factor m between beginning prefabricated blank and assembling die is 0.5.
Second loading step：Backing plate is removed, is made under first piecemeal under the lower surface of mould and second piecemeal under mould
Surface is in same level.Workpiece of the initial prefabrication base after the first loading step shaping is placed in together with assembling die and added
Average rate is heated to 970 DEG C and is incubated 1.5h in hot stove.Start the loading and shaping that forcing press carries out the second loading step to workpiece.When upper
When under molding, mould is to workpiece imposed load under the second described piecemeal.Upper line journey terminates rear pressurize 10min, subsequent forcing press
Drift backhaul, complete second loading step.The loading velocity v of the upper mould is 0.2mm/s, after the first loading step shaping
Friction factor m between workpiece and each piecemeal mould is 0.5.
Step 5, the filling after the shaping of observation initial prefabrication base and folded situation, obtain the maximum material turn for not producing folding
Shifting rate：By observing filling and folded situation after the shaping of initial prefabrication base, to obtain the maximum material transfer for not producing folding
Rate.
After two loading the end of the step, the forming results observation after being intended by described initial prefabrication mold fills and folded feelings
Condition.
Observe folded situation：Close to generating fold defect at the web of subregion muscle in the first loading zone.Obtain
Initial prefabrication base is pressed into the intrusion I of the 3rd web when not producing foldinge：
Ie=He-T2 (1)
T2For the thickness in the first loading zone close to subregion muscle web；Close to the thickness of subregion muscle web in the first loading zone
Degree is with the intrusion IeChange and change, and intrusion IeDecrement and the 3rd web thickness T2Incrementss it is identical.
By obtained IeInitial value reduce, and according to IeChange adjust the 3rd web thickness T2.The office of repeat step 3
Fold and whether produce at portion's loading and shaping process, the 3rd web of observation.If folding is still produced, the amount of will be pressed into IeInitial value is again
It is secondary to reduce, and the 3rd web thickness T is adjusted simultaneously2, untill it was observed that not producing folding.The intrusion IeInitial value is every
The value of secondary reduction is 0.1mm.
Material rate of transform M is obtained by formula (2)t：
Mt=[(Vf-Vn)/Veigen]*100 (2)
In formula：VfAfter the first loading step shaping, the original material volume in first loading zone；VfFor the second loading step
In forming process, material is transferred to after first loading zone by rear loading zone, the volume of the material.
According to obtained material rate of transform MtIt is determined that judging the critical value C of fold defectt：
Ct=α * Mt (3)
α is safety coefficient, and span is 0.95≤α ＜ 1.
Accordingly, CtAs the constraints of prefabricated blank optimization design, to avoid the fold defect of transition region.
In terms of filling, described initial prefabrication base finds unfilled areas after two loading step shapings.In order to fixed
Amount analyzes the filling situation of material, the unfilled rate Ф inscribed when being full of using certain root muscleu：
Фu=[(Veigen-Vactual)/Veigen]*100 (4)
In formula：VeigenFor the cumulative volume of transition region geometry, VactualAfter certain root muscle is full of in transition region, subtract surplus
The volume of remaining drafts material requested.
Step 6, the geometric shape design of prefabricated blank.
The prefabricated blank is divided into three regions, is respectively not blank first area, the area of non-blank second
Domain, the region of non-blank the 3rd, the thickness in each region are different, respectively H1, H2And H3.The width in each region by
lleftAnd lrightAdjusted, wherein, lleftFor second longitudinal direction muscle center line to described not blank first area length
Degree, lrightFor described second longitudinal direction muscle center line to the length in the described region of not blank the 3rd, lleftWith lright
Sum is equal to the width of described not blank second area.
The Varying-thickness area of blank does not use chamfered transition, and its transition condition is defined as：
Rb=△ l/ △ H (5)
In formula：△ l are the length of chamfering, and △ H are the thickness difference in thickening area.According to recommendation.
According to constancy of volume principle, H2As because of variate to ensure that constant volume is constant, by changing H1, H3, lleftWith
lrightFour numerical value, are distributed with the initial volume that this changes prefabricated blank.Using Box-Behnken design experimental design methods,
Draw the geometric parameter combination of the not blank under different original material distribution.It is designed go out not blank replace have
Limit the initial prefabrication base 5 in meta-model.The local loading and shaping process of repeat step 2.After local loading and shaping terminates, phase is obtained
Answer the material rate of transform M in the formula (4) and formula (5) under blanktWith unfilled rate Фu。
Step 7, response surface model is set up.
According to the result of calculation of step 6, using second order polynomial and method of gradual regression is combined, rejecting does not show to forming results
The factor of work, sets up ФuResponse surface model and MtResponse surface model.
The M of the foundationtResponse surface model be：
The Ф of the foundationuResponse surface model be：
Step 8, prefabricated blank optimizes.
With the C in formula (3)tFor constraints, the unfilled rate Ф of muscle die cavity at moment is full of with certain root muscleuFor optimization mesh
Mark, the mathematical modeling of constitution optimization design；
The mathematical model of optimizing design constructed is：
Based on MtRSM models, using step 4 obtain the maximum material rate of transform as constraints, acquisition do not producing folding
Under the conditions of folded, all dimensional parameters combination of prefabricated blank shape；, in above-mentioned parameter combination, based on ФuRSM models, adopt
With nonlinear programming approach, H is respectively obtained1、H2、H3、LleftAnd LrightValue, you can obtain the geometry of corresponding optimization prefabricated blank
Shape and the material rate of transform M of respective face model predictiontWith unfilled rate Фu。
Step 9, verify.
The accuracy and reliability of optimum results are separately verified using simplation verification and experimental verification.
Described simplation verification is：The initial prefabrication base in the FEM model is replaced with the prefabricated blank optimized.Weight
The local loading and shaping process of multiple step 2.After the shaping of two loading steps terminates, if the material rate of transform M that simulation is obtainedtIt is less than
The critical value for not producing folding, then prove that optimum results are reliable；If the unfilled rate that simulation is obtained is unfilled with prediction
Rate ФuDifference≤10%, then prove ФuResponse surface model and optimum results it is reliable..
Experimental verification：Experimental verification is carried out using lead at normal temperatures, to verify that the drip molding obtained by prefabricated blank does not produce folding
It is folded.If folding, return to step 7 re-establishes response surface model, and check the precision of the response surface model；Repeat to walk
Rapid 8, prefabricated blank optimization is re-started, until the drip molding obtained by prefabricated blank does not produce folding.
So far, the optimization process based on local loading and shaping gusset part prefabricated blank is completed.
In the present invention, the forming quality of local loading transition region plays very important effect to component performance, controls
The material flowing and gross imperfection for crossing area are to realize that isothermal local loading and shaping becomes second nature one of key of integration.Using the present invention
The prefabricated blank of institute's optimization design, can be effectively improved the uniformity of material flowing, reduce the horizontal material in transition region across muscle and flow,
Improve muscle cavity fill ability.On engineering application, it can not only improve the performance of component, and production can be reduced
Cost, can specifically obtain following effect：
(1) the issuable fold defect of gusset part local loading transition region is prevented effectively from, the bearing capacity of forging is improved；
(2) uniformity of lifting material flowing, improves muscle cavity fill, improves stock utilization；
(3) shape less-deformable alloy and complex-shaped component is typically using expensive nickel base superalloy, the optimization is set
The prefabricated blank of meter can effectively improve such mold use life-span.
(4) in forming process, the time that material is flowed freely in muscle die cavity increased, and effectively reduce press institute
The plastic force needed, therefore spent electric power can be saved, save production cost.
The prefabricated blank optimization method that the present invention is proposed for the transition region of gusset part local loading, it is titanium alloy large-sized to set up
The design of the integral prefabricated base of complex component isothermal local loading and shaping provides foundation.Relative to traditional blank design, produce
Not only cost is relatively low for the component come, and meets the demand of environmental protection, to realize the shaping one of titanium alloy large-sized complex component
Change manufacture to lay the foundation.
Brief description of the drawings
Fig. 1 is transition region geometry schematic diagram in embodiment.Wherein, Fig. 1 a are the structural representation of prefabricated blank, Fig. 1 b
It is the geometric parameter of Fig. 1 a top views, Fig. 1 c are the geometric parameters of Fig. 1 a front views.
Fig. 2 is the FEM model in embodiment.Wherein, 2a is the first loading step, and 2b is the second loading step.
Fig. 3 a are the structural representations of mould under the first piecemeal, and Fig. 3 b are the structural representations of mould under the second piecemeal.
Fig. 4 is the forming results of initial prefabrication base in embodiment.Wherein, 4a is analog result, and 4b is experimental result.
Fig. 5 is the geometry and its parameter that the prefabricated blank in embodiment is used.
Fig. 6 is the forming results for optimizing prefabricated blank.Wherein, 6a is analog result, and 6b is experimental result.
Fig. 7 is the flow chart of the present invention.In figure：
1. the first web；2. the first horizontal bar；3. first longitudinal direction muscle；4. second longitudinal direction muscle；5. the 3rd longitudinal rib；6. second
Horizontal bar；7. the 5th web；8. the plane of symmetry；9. the 6th web；10. the 4th web；11. mould blueline；12. the 3rd web；
13. the second web；14. second longitudinal direction muscle center line；15. initial prefabrication base；16. backing plate；17. mould under the first piecemeal；18. second
Mould under piecemeal；19. on mould；20. workpiece of the initial prefabrication base after the first loading step shaping；21. fold defect；22.
Thick stock material first area；23. not blank second area；24. the not region of blank the 3rd.
Embodiment
The present embodiment is primarily based on finite element modelling, and certain TA15 titanium alloy gusset is shaped using isothermal local loading method
Part, the prefabricated blank shape to transition region optimizes design.Then, the optimization prefabricated blank obtained by being verified using Physical Experiment.Tool
Body process is：
Step 1, transition region geometry is extracted.
Sun Zhi is superfine in plastic engineering journal, volume 2009,16,1 phase, delivered on page 138-143 " titanium alloy it is overall every
Frame ausforming local loading subregion is studied " find during the local loading and shaping of rib-web part, the loading zone of deformation
Effect to formed non-loading zone is a short-range effect, and its coverage is concentrated mainly on what is closed on from subregion muscle to it
In bead zone.And in the region away from subregion muscle on workpiece, it is deformed by loading zone is influenceed very little, not even by shadow
Ring, thus these regions shaping characteristic equivalent to overall loading and shaping.For the formed features of more careful reflection transition region,
The present invention is based on mentioned above principle, extracts the geometry of transition region.In the present embodiment, the transition region geometry bag extracted
Containing three longitudinal ribs and two webs between horizontal bar, and dowel and muscle, described transition region geometry and parameter
As shown in Figure 1, wherein, the first web 1, the second web 13, the 3rd web 12, the first horizontal bar 2, first longitudinal direction muscle 3 are distinguished
In first loading zone, the 4th web 10, the 5th web 7, the 6th web 9, the second horizontal bar 6, the 3rd longitudinal rib 5 difference position
In in rear loading zone.Mould blueline 2 is located in intermediate ribs.In the present embodiment, D01It is the web 1 of first longitudinal direction muscle 3 to the first
The distance at edge, D12It is muscle spacing of the first longitudinal direction muscle 3 to second longitudinal direction muscle 4, D23It is the longitudinal rib 5 of second longitudinal direction muscle 4 to the 3rd
Muscle spacing, D30It is distance distance of the 3rd longitudinal rib 5 to the edge of the 4th web 7, W1It is the width of first longitudinal direction muscle 3, W2It is
The width of second longitudinal direction muscle 4, W3It is the width of the 3rd longitudinal rib 5, W4It is the width of the first horizontal bar 2, W5It is the second horizontal bar 6
Width, H1It is the height of the horizontal bar 2 of first longitudinal direction muscle 3 and first, H2It is the height of second longitudinal direction muscle 4, H3It is the 3rd longitudinal rib
5 and second horizontal bar 6 height, T1It is the thickness of the first web 1 and the second web 13, T2It is the thickness of the 3rd web 12, T3It is
The thickness of 4th web 10, T4It is the thickness of the 5th web 7 and the 6th web 9.In addition, the withdrawing pattern oblique angle on muscle is 2 °, each muscle
The radius of corner of bar web junction adjacent thereto is 5mm.
Step 2, initial prefabrication base is designed.
Initial prefabrication base uses blank, is follow-up forming defects to observe folding and the filling effect of transition region
Control, elimination and prefabricated blank optimization provide foundation.To reduce in unhelpful material flowing, the present embodiment, blank is in the horizontal plane
Projection of shape be equal to transition region geometry projected area.The volume of known transition region geometry is 5.63*105mm3,
According to constant-volume principle, you can obtain initial prefabrication base height HeFor 23.5mm geometry external form 14.
Step 3, FEM model is set up.
The FEM model set up includes the geometric shape of assembling die and initial prefabrication base, initial prefabrication base with combining
Friction factor, upper mould between mould push speed and drafts, and initial prefabrication base temperature and the temperature of assembling die
Degree.
The center line of horizontal bar width is the plane of symmetry 8 in described component, and it is imitative to carry out simulation to the plane of symmetry side
Very, to improve computational efficiency and simulation precision.
Mould uses assembling die of the prior art, and local loading district location is located at lower mould, the mould under the first piecemeal
17 lower surface places backing plate 16, projects upwards mould 17 under the first piecemeal, and initial prefabrication base 15 is positioned over mould 19 with protruding
The first piecemeal under between mould 17.
Step 4, local loading and shaping.
First loading step：Initial prefabrication base 15 is placed in average rate in heating furnace together with assembling die and is heated to 970 DEG C simultaneously
It is incubated 1.5h.In the present embodiment, the thickness H of backing plate 16sbWith the first loading step and the drafts phase of the second loading step of mould
Deng being 14mm.If H in loadingsbThe drafts of respectively greater than first loading step and the second loading step, then whole component may
Meeting and contacting dies, make load acutely increase.This forming mode and monolithic molding are similar, it is impossible to reach local loading and shaping
Labour-saving purpose.When upper mould 19 is depressed, mould 17 is to the imposed load of initial prefabrication base 15 under the first described piecemeal.The upper row of mould 19
After journey terminates, pressurize 10min.Then, the drift backhaul of forcing press, completes the first loading step.The loading velocity v of the upper mould 19
For 0.2mm/s, the friction factor m between initial prefabrication base 15 and assembling die is 0.5.
Second loading step：Backing plate is removed, makes the lower surface of mould 17 and mould 18 under second piecemeal under first piecemeal
Lower surface be in same level.Workpiece by initial prefabrication base 15 by initial prefabrication base after the first loading step shaping
20 are placed in average rate in heating furnace together with assembling die is heated to 970 DEG C and is incubated 1.5h.Start forcing press to initial prefabrication base
Workpiece 20 after the first loading step shaping carries out the loading and shaping of the second loading step.When upper mould 19 is depressed, described
Workpiece 20 imposed load of the mould 18 to initial prefabrication base after the first loading step shaping under two piecemeals.Upper line journey is protected after terminating
10min is pressed, the drift backhaul of subsequent forcing press completes the second loading step.The loading velocity v of the upper mould 19 is 0.2mm/s, warp
Cross between workpiece 20 and each piecemeal mould of the initial prefabrication base after the first loading step shaping after the first loading step shaping
Friction factor m is 0.5.
Step 5, the filling after the shaping of observation initial prefabrication base and folded situation, obtain the maximum material turn for not producing folding
Shifting rate：By observing filling and folded situation after the shaping of initial prefabrication base, to obtain the maximum material transfer for not producing folding
Rate.
After two loading the end of the step, the forming results observation after being simulated by described initial prefabrication base 15 is filled and folded
Situation.
Folded situation：Fold defect 21 is generated at the 3rd web 12 in the first loading zone, as shown in Figure 3.
In the present embodiment, the intrusion I that initial prefabrication base 15 when not producing folding is pressed into the 3rd web 12 is obtained firste：
Ie=He-T2 (1)
T in formula (1)2With the intrusion IeChange and change, and intrusion IeDecrement and T2Increase
Amount is identical.Because the essential reason that local loading transition region produces fold defect is not loaded because the material of loading zone is transferred to
Caused by area, so fold defect can be improved or eliminate by reducing drafts.In the present embodiment, IeFor independent variable, T2For dependent variable.
I is drawn firsteInitial value be 9.5mm, reduce 0.1mm, T2It is then corresponding to increase 0.1mm, then repeat step 3 local loading
Whether forming process, fold at the 3rd web 12 of observation produce again.If folding is still produced, Ie0.1mm is reduced again, directly
Untill observing and not producing folding.Pass through analog result, Ie≤ 8.6mm can avoid fold defect.
Then, I is further calculatedeMaterial rate of transform M during for 8.6mmt：
Mt=[(Vf-Vn)/Veigen]*100 (2)
In formula：VfAfter the first loading step shaping, the original material volume in first loading zone；VfFor the second loading step
In forming process, material is transferred to after first loading end of extent by rear loading zone, volume of the material in the first loading zone.
In the present embodiment, M is calculatedtFor 4.24%, in fact, certain safe range is considered in engineer applied,
The present embodiment uses the value C smaller than 4.24%tIt is used as the critical value for judging fold defect.
Ct=4.24 α (3)
Wherein, α is safety coefficient, and span is 0.95≤α ＜ 1.Accordingly, CtIt is used as the constraint of prefabricated blank optimization design
Condition, to avoid the fold defect of transition region.
Filling situation：Described initial prefabrication base 15 is after two loading step shapings, and first indulges in the first loading zone of discovery
To the underfill of 3 and first horizontal bar of muscle 2, as shown in Figure 3..In order to which quantitative analysis goes out the filling situation of material, using certain root muscle
Full of when the unfilled rate Ф that inscribesu：
Фu=[(Veigen-Vactual)/Veigen]*100 (4)
In formula：VeigenFor the cumulative volume of transition region geometry, VactualAfter certain root muscle is full of in transition region, subtract surplus
The volume of remaining drafts material requested.In the present embodiment, described the 3rd longitudinal rib 5 and the second horizontal bar 6 is first full of, and passes through mould
Intend to show that this two muscle are full of the unfilled rate Ф at momentuFor 1.34%.
Step 6, the geometric shape design of prefabricated blank.
In the present embodiment, the geometry of optimization prefabricated blank uses the form of not uniform thickness, and its shape and structure is with letter
Single staircase structural model changes sotck thinkness distribution, is easy to processing and manufacturing, while can meet the reasonable distribution of original material again.Root
According to the planform and volume equal principle of not blank, five size variables ginseng of influence prefabricated blank volume distributed median is obtained
Number, shown in such as Fig. 4 (b).The prefabricated blank is divided into three regions, is respectively not blank first area 22, the thick stock such as not
Expect second area 23, the not region 24 of blank the 3rd；The thickness in each region is different, respectively H1, H2And H3.In addition,
The width in each region is by lleftAnd lrightAdjusted, wherein, lleftWith lrightSum is equal to the described area of not blank second
Width, the l in domain 23leftFor described second longitudinal direction muscle 4 center line 21 to described not blank first area 22 length
Degree, lrightFor described second longitudinal direction muscle 4 center line 21 to the described region 24 of not blank the 3rd length.
Zhang Dawei etc. is in The International Journal of Advanced Manufacturing
Technology, volume 63,1 phase, the Deformation behavior of variable- delivered on page 1-12 in 2012
thickness region of billet in rib-web component isothermal local loading
In process papers, local refinement is carried out to the grid in not blank Varying-thickness area using Finite Element Method, found down
Angle interim form is conducive to the generation for avoiding folding, and the Varying-thickness area of blank may be more not pervasive using chamfered transition
Property.Its transition condition is defined as：
Rb=△ l/ △ H (5)
In formula：△ l are the length of chamfering, and △ H are the thickness difference in thickening area.According to recommendation, in the present embodiment,
Thick stock material Varying-thickness area transition condition RbTake 2.
In the present embodiment, according to constancy of volume principle, H2, to ensure that constant volume is constant, pass through change as because of variate
H1, H3, lleftAnd lrightFour numerical value, are distributed with the initial volume that this changes prefabricated blank.The present embodiment is using relative value as setting
Count variable, wherein variable a:H1/HeWith variable b:H2/HeSpan be 0.75~1.15, variable c:lleft/LleftAnd change
Measure d:lright/LrightSpan be 0.6~1, wherein Lleft=D12+W2/2,Lright=D23+W2/2.Ferreira etc.
In Analytica Chimica Acta, 2007；Volume 597,2 phases, the Box-Behnken delivered on page 138-143
design:Discussed in an alternative for the optimization of analytical methods papers
Box-Behnken design experimental design methods relative to other experimental design methods advantage, therefore in the present embodiment,
Using Box-Behnken design experimental design methods, the several of not blank under 29 groups of different original materials distribution are drawn
What parameter combination.It is designed go out not blank replace initial prefabrication base 5 described in Fig. 2.Then, the present embodiment is repeated
The local loading and shaping process of middle step 2.After local loading and shaping terminates, the formula (4) and formula (5) under respective blanks are obtained
In MtAnd ФuResult.
Step 7, response surface model is set up.
Response surface meth od is the comprehensive optimization method of a kind of combination Optimum Theory and Modern Statistical Methods, its sound constructed
Answer surface model more can accurately obtain the incidence relation between variate-value and optimization aim, have been widely used engineering field and work as
In.Therefore, the result of calculation according to step 6 in the present embodiment, using second order polynomial and combines method of gradual regression, reject into
The inapparent factor of shape result, sets up ФuAnd MtResponse surface model：
It can be seen from variance analysis, the adjustment multiple correlation coefficient adjust R of two models2It is all higher than 0.9.Moreover, carrying out
5 groups of random experiments, repeat the step 4 in the present embodiment, it is found that model predication value closely, is said with finite element modelling value
Bright two models are respectively provided with higher precision of prediction, described variable a, b, c and d and ФuAnd MtIncidence relation thus built
It is vertical, therefore without time-consuming finite element modelling, the two models can replace formula (4) and formula (5), predict corresponding prefabricated blank shape
Ф under shapeuAnd MtThe result of two values.
Step 8, prefabricated blank optimizes.
First, based on MtRSM models, using the maximum material rate of transform as constraints, acquisition do not producing folded condition
Under, all dimensional parameters combination of prefabricated blank shape.Secondly, with the C in formula (3)tFor constraints, when being full of with certain root muscle
The unfilled rate Ф of muscle die cavity at quarteruFor optimization aim, the mathematical modeling of constitution optimization design：
In the above-mentioned parameter combination for not producing under folding, based on ФuRSM models, using nonlinear programming approach, meter
Calculate H1=26.7mm, H2=22.5mm, H3=22.5mm, Lleft=74mm, Lright=70mm, you can obtain corresponding optimization pre-
The geometry of base simultaneously draws material rate of transform MtFor 4.15%, less than the maximum material rate of transform for not producing folding
4.24%, unfilled rate ФuPredicted value is 0.90%, relative to initial prefabrication base, stowage capacity lifting 32.8%.
Step 9, simulation and experimental verification.
The accuracy and reliability of optimum results are separately verified using simulation and experiment.
Simplation verification：The initial prefabrication base 15 in the FEM model is replaced with the prefabricated blank optimized.Repeat step 2
Local loading and shaping process.After the shaping of two loading steps terminates, if the material rate of transform M that simulation is obtainedtLess than it is described not
The critical value folded is produced, then proves that optimum results are reliable；If simulating obtained unfilled rate and the unfilled rate Ф of predictionu's
Difference≤10%, then prove that optimum results are reliable.
In the present embodiment, after the shaping of two loading steps terminates, measured material rate of transform MtFor 4.20%, less than not
The maximum material rate of transform 4.24% folded is produced, and analog result shows and does not produce fold defect；Unfilled rate ФuFor
0.88%, differ 2.22% with predicted value.
Experimental verification：Experimental verification is carried out using lead at normal temperatures, to verify that the drip molding obtained by prefabricated blank does not produce folding
It is folded.If folding, return to step 7 re-establishes response surface model, and check the precision of the response surface model；Repeat to walk
Rapid 8, prefabricated blank optimization is re-started, until the drip molding obtained by prefabricated blank does not produce folding.The experimental verification of the present embodiment is such as
Shown in Fig. 5, drip molding does not produce folding, and filling is improved.So far, complete prefabricated based on local loading and shaping gusset part
The optimization process of base.
By above-mentioned simulation and experimental verification it was determined that the present embodiment is used for the prefabricated blank of local loading transition region
Optimization method is feasible.
Claims (6)
1. a kind of optimization method based on local loading and shaping gusset part prefabricated blank, it is characterised in that detailed process is：
Step 1, transition region geometry is extracted；
Step 2, initial prefabrication base is designed；
Initial prefabrication base uses blank；The projection of shape of blank in the horizontal plane is equal to the perspective plane of transition region geometry
Product；
Step 3, FEM model is set up：
The FEM model set up includes geometric shape, initial prefabrication base and the assembling die of assembling die and initial prefabrication base
Between friction factor, the temperature for pushing speed and drafts, initial prefabrication base and assembling die of upper mould；In described component
The center line of horizontal bar width is the plane of symmetry, and analog simulation is carried out to the plane of symmetry side；Mould is using in the prior art
Assembling die, local loading district location be located at lower mould, under the first piecemeal mould lower surface place backing plate, make the first piecemeal
Lower mould is projected upwards, and initial prefabrication base is positioned under the first piecemeal of mould and protrusion between mould；
Step 4, local loading and shaping：
The local loading and shaping has two loading steps：
First loading step：Initial prefabrication base is placed in into average rate in heating furnace together with assembling die to be heated to 970 DEG C and be incubated
1.5h；When under upper molding, mould is to initial prefabrication base imposed load under the first described piecemeal；After upper line journey terminates, pressurize
10min；Then, the drift backhaul of forcing press, completes the first loading step；The loading velocity v of the upper mould is 0.2mm/s, initially
Friction factor m between prefabricated blank and assembling die is 0.5；
Second loading step：Backing plate is removed, makes the lower surface of the lower surface of mould and mould under second piecemeal under first piecemeal
In same level；Workpiece of the initial prefabrication base after the first loading step shaping is placed in heating furnace together with assembling die
Middle average rate is heated to 970 DEG C and is incubated 1.5h；Start the loading and shaping that forcing press carries out the second loading step to workpiece；When upper molding
When lower, mould is to workpiece imposed load under the second described piecemeal；Upper line journey terminates rear pressurize 10min, and subsequent forcing press is rushed
Head backhaul, completes the second loading step；The loading velocity v of the upper mould is 0.2mm/s, the workpiece after the first loading step shaping
Friction factor m between each piecemeal mould is 0.5；
Step 5, the filling after the shaping of observation initial prefabrication base and folded situation：
By observing filling and folded situation after the shaping of initial prefabrication base, to obtain the maximum material transfer for not producing folding
Rate；
After two loading the end of the step, forming results observation filling and folded situation after being intended by described initial prefabrication mold；
Observe folded situation：Close to generating fold defect at the web of subregion muscle in the first loading zone.Obtain first
Initial prefabrication base is pressed into the intrusion I of the web when not producing foldinge：
Ie=He-T2 (1)
T2For the thickness in the first loading zone close to subregion muscle web；In the first loading zone close to subregion muscle web thickness with
The intrusion IeChange and change, and intrusion IeDecrement and the 3rd web thickness T2Incrementss it is identical；
By obtained IeInitial value reduce, and according to IeChange adjust the 3rd web thickness T2；The part of repeat step 3 adds
Carry to fold at forming process, the 3rd web of observation and whether produce；If folding is still produced, the amount of will be pressed into IeInitial value subtracts again
It is small, and the 3rd web thickness T is adjusted simultaneously2, untill it was observed that not producing folding；The intrusion IeInitial value subtracts every time
Small value is 0.1mm；
Material rate of transform M is obtained by formula (2)t：
Mt=[(Vf-Vn)/Veigen]*100 (2)
In formula：VfAfter the first loading step shaping, the original material volume in first loading zone；VfFor the second loading step shaping
During, material is transferred to after first loading zone by rear loading zone, the volume of the material；
According to obtained material rate of transform MtIt is determined that judging the critical value C of fold defectt：
Ct=α * Mt (3)
Described Ct=α Mt；α is safety coefficient, and span is 0.95≤α ＜ 1；
Accordingly, CtAs the constraints of prefabricated blank optimization design, to avoid the fold defect of transition region；
In terms of filling, described initial prefabrication base finds unfilled areas after two loading step shapings；For quantitative point
Separate out the filling situation of material, the unfilled rate Ф inscribed when being full of using certain root muscleu：
Фu=[(Veigen-Vactual)/Veigen]*100 (4)
In formula：VeigenFor the cumulative volume of transition region geometry, VactualAfter certain root muscle is full of in transition region, remaining pressure is subtracted
The volume of lower amount material requested；
Step 6, the geometric shape design of prefabricated blank：
The prefabricated blank is divided into three regions, is respectively not blank first area, non-blank second area, no
The region of blank the 3rd, the thickness in each region is different, respectively H1, H2And H3；The width in each region is by lleftWith
lrightAdjusted, wherein, lleftFor length of the center line to described not blank first area of second longitudinal direction muscle, lright
For described second longitudinal direction muscle center line to the length in the described region of not blank the 3rd, lleftWith lrightSum is equal to
The width of described not blank second area；
The Varying-thickness area of blank does not use chamfered transition, and its transition condition is defined as：
Rb=△ l/ △ H (5)
In formula：△ l are the length of chamfering, and △ H are the thickness difference in thickening area；According to recommendation；
According to constancy of volume principle, H2As because of variate to ensure that constant volume is constant, by changing H1, H3, lleftAnd lrightFour
Individual numerical value, is distributed with the initial volume that this changes prefabricated blank；Using Box-Behnken design experimental design methods, draw not
The geometric parameter combination of not blank under being distributed with original material；It is designed go out not blank replace finite element mould
Initial prefabrication base 5 in type；The local loading and shaping process of repeat step 2；After local loading and shaping terminates, respective blanks are obtained
Under formula (4) and formula (5) in material rate of transform MtWith unfilled rate ФuResult；
Step 7, response surface model is set up：
According to the result of calculation of step 6, using second order polynomial and method of gradual regression is combined, rejected inapparent to forming results
Factor, sets up ФuResponse surface model and MtResponse surface model；
Step 8, prefabricated blank optimizes：
With the C in formula (3)tFor constraints, the unfilled rate Ф of muscle die cavity at moment is full of with certain root muscleuFor optimization aim, structure
Make the mathematical modeling of optimization design；
Based on MtRSM models, using step 4 obtain the maximum material rate of transform as constraints, acquisition do not producing folded condition
Under, all dimensional parameters combination of prefabricated blank shape；, in above-mentioned parameter combination, based on ФuRSM models, using non-thread
Property planing method, respectively obtains H1、H2、H3、LleftAnd LrightValue, you can obtain corresponding optimization prefabricated blank geometry and
The material rate of transform M of respective face model predictiontWith unfilled rate Фu；
Step 9, verify：
The accuracy and reliability of optimum results are separately verified using simplation verification and experimental verification；
Described simplation verification is：The initial prefabrication base in the FEM model is replaced with the prefabricated blank optimized；Repeat to walk
Rapid 2 local loading and shaping process；After the shaping of two loading steps terminates, if the material rate of transform M that simulation is obtainedtLess than described
The critical value of folding is not produced, then proves that optimum results are reliable；If simulating obtained unfilled rate and the unfilled rate Ф of predictionu
Difference≤10%, then prove ФuResponse surface model and optimum results it is reliable；
So far, the optimization process based on local loading and shaping gusset part prefabricated blank is completed.
2. the optimization method as claimed in claim 1 based on local loading and shaping gusset part prefabricated blank, it is characterised in that
The M of the foundationtResponse surface model be：
Mt=-2.86361+7.12846a+9.84596b-2.49595c+4.24479d-6.14361ab
+2.44892ac-1.92904bd-2.96887a2-1.41188b2-1.39701d2 (6)。
The Ф of the foundationuResponse surface model be：
3. the optimization method as claimed in claim 1 based on local loading and shaping gusset part prefabricated blank, it is characterised in that step 8
The mathematical model of optimizing design of middle construction is：
4. the optimization method as claimed in claim 1 based on local loading and shaping gusset part prefabricated blank, it is characterised in that described to build
During vertical FEM model, using the center line of horizontal bar width in described component as the plane of symmetry, the plane of symmetry side is entered
Row analog simulation.
5. the optimization method as claimed in claim 1 based on local loading and shaping gusset part prefabricated blank, it is characterised in that finite element
Mould in model uses assembling die, and local loading district location is located at lower mould, and the lower surface of mould is placed under the first piecemeal
Backing plate, projects upwards mould under the first piecemeal, and initial prefabrication base is positioned under the first piecemeal of mould and protrusion between mould.
6. the optimization method as claimed in claim 1 based on local loading and shaping gusset part prefabricated blank, it is characterised in that test
Card：Experimental verification is carried out using lead at normal temperatures, to verify that the drip molding obtained by prefabricated blank does not produce folding；If folding,
Then return to step 7, re-establish response surface model, and check the precision of the response surface model；Repeat step 8, is re-started pre-
Base optimizes, until the drip molding obtained by prefabricated blank does not produce folding.
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