CN109002581A - High temperature alloy non-standard fastener Plastic Forming Reverse Design based on emulation - Google Patents
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Abstract
本发明属于金属材料加工技术领域，涉及一种基于仿真的高温合金非标紧固件塑性成形逆向设计方法。本发明通过数值模拟方法逆向设计非标紧固件成形模具及工艺，克服非标紧固件模具正向设计周期长、反复试制费用高、耗时长等缺点，采用逆向设计，综合运用有限元分析技术与CAD三维建模技术，以非标紧固件产品为基础，逆向推算设计其成形模具几何特征，设计模具型腔具体尺寸以及飞边槽的位置、形状、尺寸等；建立紧固件塑性成形数值分析模型，分析非标紧固件模锻成形工艺，计算给出成形过程中材料的流动规律与应力应变特征；基于数值模拟结果对成形模具与工装进行修正与优化，最终得到最优的模具几何特征参数及其塑性成形过程关键工艺参数。
The invention belongs to the technical field of metal material processing, and relates to a simulation-based reverse design method for plastic forming of non-standard fasteners of high-temperature alloys. The present invention reversely designs non-standard fastener forming molds and processes through numerical simulation methods, overcomes the disadvantages of long forward design cycle of non-standard fastener molds, high cost of repeated trial production, and long time consumption, adopts reverse design, and comprehensively uses finite element analysis Technology and CAD three-dimensional modeling technology, based on non-standard fastener products, reverse calculation and design of the geometric characteristics of the forming mold, design the specific size of the mold cavity and the position, shape, size, etc. of the flash groove; establish the plasticity of the fastener The forming numerical analysis model analyzes the non-standard fastener die forging forming process, and calculates the flow law and stress-strain characteristics of the material during the forming process; based on the numerical simulation results, the forming die and tooling are corrected and optimized, and finally the optimal Die geometric characteristic parameters and key process parameters of plastic forming process.
Description
技术领域technical field
本发明属于金属材料加工技术领域，涉及一种基于仿真的高温合金非标紧固件塑性成形逆向设计方法。The invention belongs to the technical field of metal material processing, and relates to a simulation-based reverse design method for plastic forming of non-standard fasteners of high-temperature alloys.
背景技术Background technique
高温合金非标准紧固件是相对于标准紧固件而言的，标准紧固件是指结构、尺寸、画法、标记等各个方面已经完全标准化，并由专业厂生产的常用紧固件，而非标紧固件主要是国家没有定出严格的标准规格，没有相关的参数规定之外，由企业自主控制的其他紧固件。Superalloy non-standard fasteners are relative to standard fasteners. Standard fasteners refer to commonly used fasteners that have been completely standardized in terms of structure, size, drawing, marking, etc., and are produced by professional factories. Non-standard fasteners are mainly other fasteners that are independently controlled by the enterprise, except that the country has not set strict standard specifications, and there are no relevant parameter regulations.
对于高温合金非标紧固件，特别是GH4169材料，主要用于高温服役条件下的设备连接，其服役工况决定客户对于这类紧固件的高质量需求，其制作过程通常是由客户提供产品图纸，厂家根据图纸设计产品的加工模具特征、初始坯料特征以及成形工艺方法，由于非标准件客户需求参差不齐，质量控制没有统一范式，正向设计中需要凭经验反复试模，设计周期长，工序复杂且反复试制成本较高。For high-temperature alloy non-standard fasteners, especially GH4169 materials, they are mainly used for equipment connections under high-temperature service conditions. The service conditions determine the high-quality requirements of customers for such fasteners, and the production process is usually provided by customers. Product drawings, the manufacturer designs the product's processing mold characteristics, initial blank characteristics and forming process methods according to the drawings. Due to the uneven customer needs for non-standard parts, there is no unified paradigm for quality control. In the forward design, repeated mold trials are required based on experience, and the design cycle Long, complex process and high cost of repeated trial production.
近年来，数值模拟技术广泛应用与材料加工制造业，可以很好地指导金属产品工艺设计，同时结合三维建模技术完成对特定金属材料产品的模具设计及加工工艺设计，数值模拟技术的应用可以大大降低正向设计中反复试模的周期和成本，提高效率。In recent years, numerical simulation technology has been widely used in the material processing and manufacturing industry, which can guide the process design of metal products well. At the same time, combined with three-dimensional modeling technology to complete the mold design and processing technology design of specific metal material products, the application of numerical simulation technology can be Greatly reduce the cycle and cost of repeated mold trials in forward design, and improve efficiency.
以往对于标准紧固件产品，设计师通常采用正向设计方法，借用标准体系实现产品设计与工艺制定，而对于非标准紧固件产品，正向设计方法则显示了它的不足，设计过程难度系数大，周期较长、成本较高，并且正向设计中一旦出现局部性问题就要对整个方案推倒重来，时间和设计成本高昂。In the past, for standard fastener products, designers usually adopt the forward design method, and use the standard system to realize product design and process formulation. For non-standard fastener products, the forward design method shows its shortcomings, and the design process is difficult. The coefficient is large, the cycle is long, and the cost is high, and once a local problem occurs in the forward design, the entire scheme must be overthrown and restarted, and the time and design cost are high.
发明内容Contents of the invention
本发明的目的在于提供一种基于仿真的高温合金非标紧固件塑性成形逆向设计方法。以克服高温合金非标紧固件模具正向设计周期长、反复试制费用高、耗时长等缺点。The purpose of the present invention is to provide a simulation-based reverse design method for plastic forming of superalloy non-standard fasteners. To overcome the shortcomings of long forward design cycle, high cost of repeated trial production, and long time-consuming of superalloy non-standard fastener molds.
本发明的技术解决方案是：Technical solution of the present invention is:
1)首先利用数字图像处理技术提取高温合金非标紧固件产品的几何尺寸与特征，运用三维造型软件建立该紧固件的三维几何模型，运用三维造型软件计算非标紧固件的体积数值；1) First, use digital image processing technology to extract the geometric dimensions and characteristics of superalloy non-standard fastener products, use 3D modeling software to establish a 3D geometric model of the fastener, and use 3D modeling software to calculate the volume value of non-standard fasteners ;
2)基于高温合金非标紧固件的几何尺寸与特征以及步骤1)中计算的紧固件体积数值，逆向设计模具的形腔尺寸与几何特征，并计算初始坯料尺寸、飞边槽尺寸与形状，运用三维造型软件建立紧固件锻造模具三维模型以及初始坯料的三维几何模型；2) Based on the geometric dimensions and characteristics of superalloy non-standard fasteners and the fastener volume value calculated in step 1), reverse design the cavity size and geometric characteristics of the mold, and calculate the initial blank size, flash groove size and Shape, using 3D modeling software to establish a 3D model of the fastener forging die and a 3D geometric model of the initial blank;
3)将步骤2)中建立的紧固件锻造模具三维模型以及初始坯料的三维几何模型导入体积成形数值分析软件Deform中进行几何检查，根据锻造过程中上模、下模以及初始坯料的空间几何定位关系建立三者之间的装配关系，设定初始几何接触条件，采用有限元法离散坯料弹塑性体，设定模具为刚体，其中坯料采用四面体或六面体单元，定义网格重划分与自适应特征，在材料特性中定义紧固件初始坯料为高温合金材料，定义材料应力-应变曲线、热导率、热扩散率、比热容、线膨胀系数、弹性性能、氧化速率相关参数的函数关系，定义热交换边界条件，并设置运动几何特征，计算紧固件成形过程；3) Import the 3D model of the fastener forging die established in step 2) and the 3D geometric model of the initial blank into the volume forming numerical analysis software Deform for geometric inspection. According to the spatial geometry of the upper die, lower die and initial blank during the forging process The positioning relationship establishes the assembly relationship between the three, sets the initial geometric contact conditions, uses the finite element method to discretize the elastoplastic body of the blank, sets the mold as a rigid body, and uses tetrahedral or hexahedral elements for the blank, and defines the grid redivision and automatic Adaptive features, define the initial blank of the fastener as a superalloy material in the material properties, define the functional relationship of the material stress-strain curve, thermal conductivity, thermal diffusivity, specific heat capacity, linear expansion coefficient, elastic properties, and oxidation rate related parameters, Define heat exchange boundary conditions, set motion geometric features, and calculate fastener forming process;
4)基于上述数值模拟计算结果，分析高温合金非标紧固件的成形过程，给出成形过程中材料流动规律，从给出的成形过程中材料流动规律中提取高温合金非标紧固件的整体及中心截面的速度场、温度场、应力场的分布状况进行对比分析；4) Based on the above numerical simulation calculation results, analyze the forming process of superalloy non-standard fasteners, give the material flow law in the forming process, and extract the superalloy non-standard fasteners from the given material flow law in the forming process. The distribution of the velocity field, temperature field, and stress field of the overall and central sections are compared and analyzed;
5)利用上述数值分析模型并参考上述步骤4)中的计算结果，修正紧固件成形模具，优化初始坯料尺寸，从而建立优化的高温合金非标紧固件成形过程数值分析模型，重复步骤3)，4)，直到给出最优的成形模具及工艺设计方案。5) Using the above numerical analysis model and referring to the calculation results in the above step 4), correct the fastener forming die and optimize the initial blank size, thereby establishing an optimized numerical analysis model for the forming process of superalloy non-standard fasteners, and repeat step 3 ), 4), until the optimal forming die and process design scheme is given.
所述步骤1中三维建模软件可以选取Catia、UG、ProE软件，数值分析软件可选择Deform或Abaqus或其他有限元分析软件用于紧固件锻造成形工艺过程计算分析。In the step 1, the three-dimensional modeling software can choose Catia, UG, ProE software, and the numerical analysis software can choose Deform or Abaqus or other finite element analysis software for calculation and analysis of the fastener forging forming process.
所述高温合金为GH4169或GH738材料的非标紧固件塑性成形逆向设计。The high-temperature alloy is a reverse design of non-standard fastener plastic forming of GH4169 or GH738 material.
本发明具的优点和有益效果：本发明给出一种基于仿真的高温合金非标紧固件塑性成形逆向设计方法，形成基于数值模拟技术的包含逆向设计、快速模具设计、工艺设计为闭环的完整体系。对于高温合金非标紧固件的逆向设计，主要是在紧固件加工模具图纸与其塑性加工工艺参数不确定的情况下，对非标紧固件产品实物样件进行尺寸特征提取，并利用可实现逆向三维造型设计的软件来重新构造实物的三维CAD模型，并进一步运用CAE有限元分析技术实现分析、再设计、工艺确定等过程。逆向设计相对于正向设计，对产品的原始模型或者已有产品进行逆向推演，通过计算机辅助设计与制造虚拟再现非标紧固件产品的设计制造过程，从而快速寻求最优的设计方案，缩短产品研发周期，降低成本。Advantages and beneficial effects of the present invention: the present invention provides a simulation-based reverse design method for plastic forming of superalloy non-standard fasteners, forming a closed-loop system based on numerical simulation technology that includes reverse design, rapid mold design, and process design complete system. For the reverse design of high-temperature alloy non-standard fasteners, it is mainly to extract the dimensional features of the physical samples of non-standard fastener products when the drawings of fastener processing molds and their plastic processing parameters are uncertain, and use available Realize the software of reverse 3D modeling design to reconstruct the 3D CAD model of the object, and further use CAE finite element analysis technology to realize the process of analysis, redesign, process determination and so on. Compared with forward design, reverse design performs reverse deduction on the original model of the product or existing products, and simulates the design and manufacturing process of non-standard fastener products through computer-aided design and manufacturing, so as to quickly find the optimal design solution and shorten the production time. Product development cycle, reduce costs.
本方法与现有技术相比，其显著优点在于，1、本发明通过基于数值模拟的逆向设计方法，大幅度降低模具的设计成本，同时逆向设计中三维数字化设计与成形过程数值模拟相结合，可扩展性好；2、本发明大大缩短了模具的设计周期，采用本发明的设计周期一般在一周内可实现，能够很好满足当今日新月异的市场需求与环境；3、本发明通过数字化逆向设计，提高了高温合金非标紧固件成形精度与质量，并且通过数值模拟其成形过程，可以大大减小模具设计制造废品率、工艺生产中的局部问题风险等，有益实现降本增效。Compared with the prior art, this method has significant advantages in that: 1. The present invention greatly reduces the design cost of the mold through the reverse design method based on numerical simulation, and at the same time, the three-dimensional digital design is combined with the numerical simulation of the forming process in the reverse design, Good scalability; 2. The present invention greatly shortens the design cycle of the mold, and the design cycle of the present invention can generally be realized within one week, which can well meet today's ever-changing market demands and environments; 3. The present invention adopts digital reverse design , improve the forming accuracy and quality of superalloy non-standard fasteners, and through numerical simulation of its forming process, it can greatly reduce the scrap rate of mold design and manufacturing, the risk of local problems in process production, etc., which is beneficial to realize cost reduction and efficiency increase.
附图说明Description of drawings
图1是本发明设计方法的流程图；Fig. 1 is the flowchart of design method of the present invention;
图2为本发明算例中运用Catia软件对高温合金非标紧固件进行三维建模；Fig. 2 is the use of Catia software in the calculation example of the present invention to carry out three-dimensional modeling of superalloy non-standard fasteners;
图3为高温合金非标紧固件成形过程数值分析模型，其中1是上模，2是初始坯料，3是飞边槽，4是下模；Figure 3 is a numerical analysis model of the forming process of superalloy non-standard fasteners, in which 1 is the upper die, 2 is the initial blank, 3 is the flash groove, and 4 is the lower die;
图4为最优方案中基于数值计算结果的GH4169非标紧固件的塑性成形关键过程材料流动特征。Figure 4 shows the material flow characteristics of the key process of plastic forming of GH4169 non-standard fasteners based on numerical calculation results in the optimal scheme.
具体实施方式Detailed ways
下面结合具体实施方式，进一步阐述本发明。The present invention will be further described below in combination with specific embodiments.
本发明的技术方案包括以下步骤：Technical scheme of the present invention comprises the following steps:
步骤1，高温合金非标紧固件数据测量与采集，利用数字图像处理技术提取高温合金非标紧固件产品的几何尺寸与特征，运用三维造型软件建立该紧固件的三维几何模型，并运用三维造型软件计算非标紧固件的体积数值；Step 1, data measurement and collection of superalloy non-standard fasteners, using digital image processing technology to extract the geometric dimensions and characteristics of superalloy non-standard fastener products, using 3D modeling software to establish a 3D geometric model of the fastener, and Use 3D modeling software to calculate the volume value of non-standard fasteners;
步骤2，分析与模具设计，基于高温合金非标紧固件的几何尺寸与特征以及步骤1中计算的紧固件体积数值，设计模具形腔尺寸与几何特征，计算初始坯料尺寸、飞边槽尺寸与形状，运用三维造型软件建立包含飞边槽的紧固件锻造模具三维模型以及初始坯料的三维几何模型；Step 2, analysis and mold design, based on the geometric dimensions and characteristics of superalloy non-standard fasteners and the fastener volume value calculated in step 1, design the mold cavity size and geometric characteristics, and calculate the initial blank size, flash groove Size and shape, using 3D modeling software to establish a 3D model of the fastener forging die including flash grooves and a 3D geometric model of the initial blank;
步骤3，成形过程数值建模，将步骤2中建立的紧固件锻造模具三维模型以及初始坯料的三维几何模型导入体积成形数值分析软件Deform中进行几何检查，根据锻造过程中上模1，下模2以及初始坯料3的空间几何定位关系建立三者之间的装配关系，设定初始几何接触条件，采用有限元法离散坯料弹塑性体，设定模具为刚体，其中坯料采用四面体或六面体单元，定义网格重划分与自适应特征。在材料特性中定义紧固件初始坯料(如GH4169、GH738等)材料，定义材料应力应变曲线、热导率、热扩散率、比热容、线膨胀系数、弹性性能、氧化速率等相关参数的函数关系，定义热交换边界条件，并设置运动几何特征，计算紧固件成形过程；Step 3: Numerical modeling of the forming process. Import the 3D model of the fastener forging die established in Step 2 and the 3D geometric model of the initial blank into the volume forming numerical analysis software Deform for geometric inspection. The spatial geometric positioning relationship between the mold 2 and the initial blank 3 establishes the assembly relationship between the three, sets the initial geometric contact conditions, uses the finite element method to discretize the elastic-plastic body of the blank, and sets the mold as a rigid body, in which the blank adopts tetrahedron or hexahedron Elements, defining remeshing and adaptive features. Define the material of the initial blank of the fastener (such as GH4169, GH738, etc.) in the material properties, and define the functional relationship of the material stress-strain curve, thermal conductivity, thermal diffusivity, specific heat capacity, linear expansion coefficient, elastic properties, oxidation rate, etc. , define the heat exchange boundary conditions, and set the motion geometry features to calculate the fastener forming process;
步骤4，模拟结果分析，基于上述数值模拟计算结果，分析高温合金非标紧固件的成形过程，给出成形过程中材料流动规律，从给出的成形过程中材料流动规律中提取高温合金非标紧固件的整体及中心截面的速度场、温度场、应力场的分布状况进行对比分析，研究成形过程中出现的缺陷包括充不满、折叠、欠压等缺陷与成形模具与工艺参数的影响规律；Step 4, analysis of simulation results. Based on the above numerical simulation calculation results, analyze the forming process of superalloy non-standard fasteners, give the material flow law in the forming process, and extract the superalloy non-standard fasteners from the given material flow law in the forming process. Compare and analyze the distribution of the velocity field, temperature field, and stress field of the overall and central section of the standard fastener, and study the defects that occur during the forming process, including defects such as insufficient filling, folding, and underpressure, and the influence of forming molds and process parameters. law;
步骤5，反馈与修正优化，利用上述分析模型并参考上述计算与分析结果，修正非标紧固件成形模具及飞边槽尺寸，回到步骤2，优化初始坯料尺寸，从而建立优化的非标紧固件成形过程数值分析模型，重复步骤3，步骤4，优化成形工艺过程参数，包括锻造温度、锻造速度，最终给出最优的成形模具及工艺设计方案。Step 5, feedback and correction optimization, using the above analysis model and referring to the above calculation and analysis results, correct the size of the non-standard fastener forming die and flash groove, return to step 2, optimize the initial blank size, and establish the optimized non-standard Numerical analysis model of the fastener forming process, repeat steps 3 and 4, optimize the parameters of the forming process, including forging temperature and forging speed, and finally give the optimal forming die and process design scheme.
实施例Example
本发明公开一种基于仿真的高温合金非标紧固件塑性成形逆向设计方法，具体实施步骤如下：The invention discloses a simulation-based reverse design method for plastic forming of superalloy non-standard fasteners. The specific implementation steps are as follows:
步骤1，高温合金GH4169非标紧固件数据测量与采集，利用数字图像处理技术提取高温合金GH4169非标紧固件产品的几何尺寸与特征，运用三维造型软件Catia建立该紧固件的三维几何模型，如图2所示，并运用三维造型软件Catia计算非标紧固件的体积数值；Step 1, data measurement and collection of superalloy GH4169 non-standard fasteners, using digital image processing technology to extract the geometric dimensions and characteristics of superalloy GH4169 non-standard fasteners, and using the 3D modeling software Catia to establish the 3D geometry of the fasteners Model, as shown in Figure 2, and use the three-dimensional modeling software Catia to calculate the volume value of non-standard fasteners;
步骤2，分析与模具设计，基于高温合金GH4169非标紧固件的几何特征与尺寸以及步骤1中计算的紧固件体积数值，设计模具形腔尺寸与几何特征，计算初始坯料尺寸、飞边槽尺寸与形状，运用Catia软件建立包含飞边槽的紧固件锻造模具三维模型以及初始坯料的三维几何模型，分别以*.stl或*.igs格式导出存储；Step 2, analysis and mold design, based on the geometric characteristics and dimensions of superalloy GH4169 non-standard fasteners and the fastener volume value calculated in step 1, design the mold cavity size and geometric characteristics, and calculate the initial blank size and flash Groove size and shape, use Catia software to build the 3D model of the fastener forging die including the flash groove and the 3D geometric model of the initial blank, export and store in *.stl or *.igs format respectively;
步骤3，成形过程数值建模，将步骤2中建立的紧固件锻造模具三维模型以及初始坯料的三维几何模型以*.stl格式或*.igs格式导入体积成形数值分析软件Deform中进行几何检查(geometry check)，根据锻造过程中上模1，下模4以及初始坯料2的空间几何定位关系建立三者之间的装配关系，如图3所示，设定初始几何接触条件，采用有限元法离散坯料弹塑性体，设定模具为刚体，其中坯料采用四面体单元，定义网格重划分与自适应特征。在材料特性中定义紧固件初始坯料为GH4169材料，定义材料应力-应变曲线、热导率、热扩散率、比热容、线膨胀系数、弹性性能、氧化速率等相关参数的函数关系，定义热交换边界条件，并设置运动几何特征，生成数据库提交求解器，计算紧固件成形过程；Step 3, numerical modeling of the forming process, import the 3D model of the fastener forging die established in step 2 and the 3D geometric model of the initial blank into the volume forming numerical analysis software Deform in *.stl format or *.igs format for geometric inspection (geometry check), according to the spatial geometric positioning relationship of upper die 1, lower die 4 and initial blank 2 in the forging process, establish the assembly relationship between the three, as shown in Figure 3, set the initial geometric contact conditions, and use finite element Discretize the elastoplastic body of the billet by using the method, set the mold as a rigid body, and the billet adopts tetrahedral elements, and define the remeshing and self-adaptive features. In the material properties, define the initial blank of the fastener as GH4169 material, define the functional relationship of the material stress-strain curve, thermal conductivity, thermal diffusivity, specific heat capacity, linear expansion coefficient, elastic properties, oxidation rate and other related parameters, and define the heat exchange Boundary conditions, and set motion geometric features, generate database and submit solver, calculate fastener forming process;
步骤4，模拟结果分析，基于上述数值模拟计算结果，分析高温合金非标紧固件的成形过程，给出成形过程中材料流动规律，从给出的成形过程中材料流动规律中提取高温合金非标紧固件的整体及中心截面的速度场、温度场、应力场的分布状况进行对比分析，研究成形过程中出现的缺陷包括充不满、折叠、欠压等缺陷与成形模具与工艺参数的影响规律；Step 4, analysis of simulation results. Based on the above numerical simulation calculation results, analyze the forming process of superalloy non-standard fasteners, give the material flow law in the forming process, and extract the superalloy non-standard fasteners from the given material flow law in the forming process. Compare and analyze the distribution of the velocity field, temperature field, and stress field of the overall and central section of the standard fastener, and study the defects that occur during the forming process, including defects such as insufficient filling, folding, and underpressure, and the influence of forming molds and process parameters. law;
步骤5，反馈与修正优化，利用上述分析模型并参考上述计算结果，修正紧固件成形模具及飞边槽尺寸，回到步骤2，优化初始坯料尺寸，从而建立优化的GH4169非标紧固件成形过程数值分析模型，重复步骤3，步骤4，优化成形工艺过程参数，包括锻造温度和锻造速度，最终给出最优的成形模具及工艺设计方案。图4为最优方案中基于数值计算结果的GH4169非标紧固件的塑性成形关键过程材料流动特征。Step 5, feedback and correction optimization, use the above analysis model and refer to the above calculation results, correct the size of the fastener forming die and the flash groove, return to step 2, optimize the initial blank size, so as to establish the optimized GH4169 non-standard fastener Numerical analysis model of the forming process, repeat steps 3 and 4, optimize the parameters of the forming process, including forging temperature and forging speed, and finally give the optimal forming die and process design scheme. Figure 4 shows the material flow characteristics of the key process of plastic forming of GH4169 non-standard fasteners based on numerical calculation results in the optimal scheme.
对实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本发明中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本发明所示的实施例，而是要符合与本发明所公开的原理和新颖特点相一致的最宽权利范围。Various modifications to the embodiments will be readily apparent to those skilled in the art, and the general principles defined in this invention may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention will not be limited to the illustrated embodiments of the present invention, but will comply with the broadest scope of rights consistent with the disclosed principles and novel features of the present invention.
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