CN112989515B - Prediction method for space envelope metal flow and high-rib growth of thin-wall multilayer high-rib component - Google Patents

Prediction method for space envelope metal flow and high-rib growth of thin-wall multilayer high-rib component Download PDF

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CN112989515B
CN112989515B CN202110250830.XA CN202110250830A CN112989515B CN 112989515 B CN112989515 B CN 112989515B CN 202110250830 A CN202110250830 A CN 202110250830A CN 112989515 B CN112989515 B CN 112989515B
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韩星会
华林
庄武豪
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Wuhan University of Technology WUT
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Abstract

The invention relates to a prediction method for space envelope metal flow and high-rib growth of a thin-wall multilayer high-rib component, which comprises the following steps of: s1, decomposing the thin-wall multilayer high-rib component into a plurality of areas; s2, mixing IIBThe region abstraction is a corner extrusion model, and a deformation power method is adopted to derive IIBHorizontal pressing force q on the interface of zone and zone IIInDeriving the horizontal extrusion force q on the interface of IV and III regions by deformationw(ii) a S3, determination of IIIAZone radial stress σr_nDistribution equation and IIIBZone radial stress σr_wA distribution equation; s4, establishing a relation equation of a diversion surface and a confluence surface; s5, solving the flow surface position r when the thickness of the thin bottom plate is H in the space envelope forming process of the thin-wall multilayer high-rib componentg(H) (ii) a And S6, obtaining the height of the outer layer high rib of the envelope-formed thin-wall multi-layer high rib component. The method can accurately predict the metal flowing process of the space enveloping forming of the thin-wall multilayer high-rib component and the synergistic growth process of the multilayer high-rib, and provides a basis for the optimization design of the space enveloping forming process condition of the thin-wall multilayer high-rib component and the optimization design of the mold structure.

Description

Prediction method for space envelope metal flow and high-rib growth of thin-wall multilayer high-rib component
Technical Field
The invention relates to the field of forming and manufacturing of thin-wall multilayer high-rib components, in particular to a prediction method for space envelope metal flow and high-rib growth of a thin-wall multilayer high-rib component.
Background
The thin-wall multilayer high-rib component is a typical structural component with a thin bottom plate and a multilayer high-rib structure, and is widely applied in the fields of aerospace, weaponry, precision machine tools and the like. Due to the complex geometric shape of the thin-wall multilayer high-rib member, the traditional manufacturing method is cutting processing. However, since the manufacturing efficiency of the cutting process is low, the material yield is low, and a continuous metal flow line cannot be formed, it is difficult to efficiently manufacture a thin-walled multilayer high-rib member with high quality by the cutting process. In order to realize efficient and high-quality manufacturing of thin-wall multi-layer high-rib components, researchers have proposed to replace cutting with a space envelope forming process in recent years. However, in the process of forming the thin-wall multi-layer high-rib member by space envelope, the metal flow is very complex due to the complex geometric shape of the member and the space envelope motion of a multi-degree-of-freedom mold, the growth process among the multi-layer high ribs is obviously asynchronous, and the forming defects such as insufficient filling of the high ribs, rib penetration, streamline disorder and the like are easily generated. In order to avoid the forming defects, the flowing and the growing of the space enveloping forming metal of the thin-wall multilayer high-rib component must be accurately predicted, so that a basis is provided for the space enveloping forming process condition optimization design and the mold structure optimization design of the thin-wall multilayer high-rib component.
Disclosure of Invention
The invention aims to solve the technical problem of providing a prediction method for the space enveloping metal flowing and the high rib growing of a thin-wall multilayer high rib component, which can accurately predict the space enveloping forming metal flowing process and the multilayer high rib cooperative growing process of the thin-wall multilayer high rib component and provide a basis for the space enveloping forming process condition optimization design and the mold structure optimization design of the thin-wall multilayer high rib component, thereby effectively avoiding the forming defects of insufficient high rib filling, rib penetrating, streamline disorder and the like.
The technical scheme adopted by the invention for solving the technical problems is as follows: a prediction method for space envelope metal flow and high-rib growth of a thin-wall multilayer high-rib component is constructed, and comprises the following steps:
s1, decomposing the thin-wall multilayer high-rib component into a plurality of areas, wherein the area I is a thin baseplate area within the inner-layer high ribs, the area II is an inner-layer high rib area, the area III is a thin baseplate area between the inner-layer high ribs and the outer-layer high ribs, and the area IV is an outer-layer high rib area; dividing II into II areas by using the convergent plane as a boundaryAInner zone and IIBThe outer zone is divided into III zones by using the flow dividing surface as a boundaryAInner ring zone and IIIBAn outer ring area;
s2, mixing IIBThe region abstraction is a corner extrusion model, and a deformation power method is adopted to derive IIBHorizontal pressing force q on the interface of zone and zone IIInObtaining qnSolving equation (1); in the same way, the IV area is abstracted into a corner extrusion model, and the horizontal extrusion force q on the interface of the IV area and the III area is deduced by adopting a deformation power methodwObtaining qwSolving equation (2);
Figure BDA0002965998970000021
Figure BDA0002965998970000022
wherein H is the thickness of the thin bottom plate at any instant of envelope forming, r2Is the outer surface radius of the inner high rib, bwIs the thickness of the outer layer high rib, rpDividing the radius of the flow surface for enveloping any instant II, wherein K is the yield strength of the material, and m is the shear friction coefficient;
s3, abstracting the III area into a ring upsetting model with an inner cylindrical surface and an outer cylindrical surface bearing radial constraint loads, wherein the inner cylindrical surface radial constraint loads are q obtained in the step S2nThe outer cylindrical surface radial restraining load is q obtained in step S2w(ii) a Inner ring zone III by main stress methodAAnd the outer annular region IIIBRadial stress analysis is carried out to obtain IIIAZone radial stress σr_nDistribution equations (3) and IIIBZone radial stress σr_wDistribution equation (4);
Figure BDA0002965998970000023
Figure BDA0002965998970000031
wherein x is the radial distance from any position in zone III to the axis of the member, r3Is the radius of the inner surface of the outer high rib, rgFlow surface radius is distinguished for envelope forming at any instant III;
s4, according to two sides II of the inner-layer high-rib converging surfaceAZone and IIBThe metal in the zone must keep the same height condition at any time of envelope forming, and a relation equation (5) of a flow dividing surface and a converging surface is established;
Figure BDA0002965998970000032
wherein r is1The radius of the inner surface of the inner layer high rib;
s5 according to the flow distribution surface rgIn a stress equilibrium condition in which the radial forces on the left and right sides are equal in magnitude, i.e.
Figure BDA0002965998970000035
Simultaneously satisfies the relation equation (5) of the flow dividing surface and the flow converging surface established in the step S4, and solves the position r of the flow dividing surface when the thickness of the thin bottom plate is H in the space envelope forming process of the thin-wall multilayer high-rib componentg(H)；
S6, the step S5 is executed to obtain rg(H) Substituting equation (6) to obtain the height of the inner layer high rib of the envelope-formed thin-wall multilayer high rib component; step S6 is performed to obtain rgSubstituting equation (7) to obtain the height of the outer layer high rib of the envelope-formed thin-wall multilayer high rib component;
Figure BDA0002965998970000033
Figure BDA0002965998970000034
wherein H0Is the initial thickness of the blank, HtIs the final thickness of the thin bottom plate.
In the scheme, a thin-wall multilayer high-rib component is manufactured by adopting a space envelope forming process, and a mould of the thin-wall multilayer high-rib component consists of an envelope convex mould and a concave mould; the bottom surface of the thin bottom plate and the outer surface of the outer layer high rib of the thin-wall multilayer high rib component are formed by a female die, the other molded surfaces are formed by an enveloping male die, the female die is required to be positioned below, and the enveloping male die is positioned above; the enveloping convex die is a conical die body, and rotates around the axis of the blank while rotating around the axis of the enveloping convex die, so that space enveloping motion is realized; the female die cavity is determined by the bottom surface of the thin bottom plate of the thin-wall multilayer high-rib component and the outer surface of the outer layer high-rib component, and the female die pushes the blank to move upwards along the axial direction; under the action of the axial motion of the female die and the space enveloping motion of the enveloping male die, the blank is subjected to plastic deformation, and the thin-wall multilayer high-rib component is gradually formed.
In the scheme, the blank for space enveloping and forming of the thin-wall multilayer high-rib component is a thick plate with uniform thickness, the shape of the axial section of the thick plate is the same as that of the axial section of the thin bottom plate, the blank is placed in the female die, the circumferential profile of the blank must be in contact with the side wall of the female die, and the bottom surface of the blank is in contact with the bottom surface of the female die.
In the scheme, in the space enveloping forming process of the thin-wall multilayer high-rib component, the contact area of the enveloping male die and the blank is not less than 75% of the area of the upper surface of the blank.
In the scheme, the taper angle alpha of the enveloping convex die is not less than 178 degrees.
The method for predicting the space envelope metal flow and the high-rib growth of the thin-wall multilayer high-rib component has the following beneficial effects:
(1) the method for predicting the rib height in the space envelope forming of the thin-wall multilayer high-rib component can accurately predict the metal flow rule and the growth process of the multilayer high rib in the space envelope forming of the thin-wall multilayer high-rib component, thereby effectively avoiding the forming defects of insufficient filling of the high rib, rib penetration, streamline disorder and the like.
(2) The prediction method for the space enveloping forming rib height of the thin-wall multilayer high-rib component provided by the invention can provide a basis for the optimization design of the space enveloping forming process condition of the thin-wall multilayer high-rib component and the optimization design of the mold structure, thereby obviously improving the product quality and the manufacturing efficiency of the thin-wall multilayer high-rib component.
Drawings
The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic view of the geometry of a thin-walled multi-layered high-rib structure;
FIG. 2 is a schematic view of the space envelope forming of a thin-walled multi-layer high-rib member;
FIG. 3 is a sectional view of a thin-walled multi-layered high-rib member;
FIG. 4 is a schematic diagram of a thin-wall multi-layer high-rib component space envelope forming corner extrusion model;
FIG. 5 is a schematic diagram of a thin-wall multilayer high-rib component space envelope forming III-region radial constraint ring upsetting model
FIG. 6 is a graph of the variation of the space envelope forming rib height of the thin-wall multilayer high rib component.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
The target thin-walled multi-layered high-rib member in this example is composed of a thin base plate 1, an inner-layered high rib 2 and an inner-layered high rib 3, and its geometry is shown in fig. 1, and its main geometry is shown in table 1.
S1, manufacturing a thin-wall multilayer high-rib component by adopting a space envelope forming process, wherein a schematic diagram of space envelope forming of the thin-wall multilayer high-rib component is shown in figure 2, the bottom surface of a thin bottom plate 1 and the outer surface of an inner layer high rib 3 of the thin-wall multilayer high-rib component are formed by a female die 4, other molded surfaces are formed by an envelope male die 5, the female die 4 is required to be positioned below, and the envelope male die 5 is positioned above; the blank 63 for space enveloping forming of the thin-wall multilayer high-rib component is a thick plate with uniform thickness, the shape of the axial section of the thick plate is the same as that of the axial section of the thin bottom plate 1, the blank 6 is placed in the female die 4, the circumferential profile of the blank 6 is required to be contacted with the side wall of the female die 4, and the bottom surface of the blank 6 is contacted with the bottom surface of the female die 4; the enveloping male die 5 is a tapered die body, and the taper angle alpha of the enveloping male die is 179 degrees. The enveloping male die 5 acts on the upper surface of the blank 6 and rolls on the upper surface of the blank 6 in multiple cycles by taking the axis of the blank 6 as a rotating shaft, the female die 4 pushes the blank 6 to move upwards along the axial direction, and the feeding speed of the female die is 2mm/s, so that the contact area between the enveloping male die 5 and the blank 6 is ensured to be not less than 75% of the area of the upper surface of the blank 6.
Table 1: major dimension of thin-wall multi-layer high-rib component
Figure BDA0002965998970000051
And S2, decomposing the thin-wall multi-layer high-rib component into 6 regions, as shown in figure 3. I is a region ofThe thin bottom plate 1 area within the inner layer high rib 2, the area II is the inner layer high rib 2 area, the area III is the thin bottom plate 1 area between the inner layer high rib 2 and the outer diameter, and the area IV is the inner layer high rib 3 area. With the confluence surface 8 as a boundary, divide II into IIAInner zone and IIBThe outer zone, which is delimited by the dividing plane 7, divides III into IIIAInner ring region and IIIBAn outer annular zone.
S3, mixing IIBThe region abstraction is a corner extrusion model, and a deformation power method is adopted to derive IIBHorizontal pressing force q on the interface of zone and zone IIInObtaining qnEquation (1) is solved. In the same way, the IV area is abstracted into a corner extrusion model, and the horizontal extrusion force q on the interface of the IV area and the III area is deduced by adopting a deformation power methodwObtaining qwEquation (2) is solved.
Figure BDA0002965998970000061
Figure BDA0002965998970000062
Wherein H is the thickness of the thin bottom plate 1 at any moment of envelope forming, r2Is the outer surface radius of the inner layer high rib 2, bwThe thickness of the inner layer high rib 3 is rpThe radius of the flow surface 7 is distinguished for any instant II of envelope forming, K is the yield strength of the material, and is 55MPa, and m is the shear friction coefficient, and is 0.4.
And S4, abstracting the III area into a circular ring upsetting model of which the inner cylindrical surface and the outer cylindrical surface bear radial constraint load, as shown in FIG. 5. Wherein the inner cylindrical surface radial restraining load is q obtained in step S3nThe outer cylindrical surface radial restraining load is q obtained in step S3w. Inner ring zone III by main stress methodAAnd the outer annular region IIIBRadial stress analysis is carried out to obtain IIIAZone radial stress σr_nDistribution equations (3) and IIIBZone radial stress σr_wDistribution equation (4).
Figure BDA0002965998970000063
Figure BDA0002965998970000064
Wherein x is the radial distance from any position in zone III to the axis of the member, r3Is the radius of the inner surface of the inner layer high rib 3, rgThe flow surface 7 radius is distinguished for any instant iii of envelope shaping.
S5, converging surfaces 8 on two sides II according to the inner-layer high ribs 2AZone and IIBAnd (3) establishing a relation equation (5) of the flow dividing surface 7 and the flow converging surface 8 under the condition that the metal in the zone must keep equal height at any moment of envelope forming.
Figure BDA0002965998970000071
Wherein r is1Is the radius of the inner surface of the inner layer high rib 2.
S6 according to the flow distribution surface 7rgIn a stress balance condition where the radial forces on the left and right sides are equal in magnitude, i.e.
Figure BDA0002965998970000072
Simultaneously satisfies the relation equation (5) of the flow distribution surface 7 and the flow convergence surface 8 established in the step S5, and solves the position r of the flow distribution surface 7 when the thickness of the thin bottom plate 1 is H in the space envelope forming process of the thin-wall multilayer high-rib componentg(H)。
S7, the step S6 is executed to obtain rg(H) And (6) substituting equation (6) to obtain the height of the inner layer high rib 2 of the envelope-formed thin-wall multi-layer high rib component. Step S6 is performed to obtain rgSubstituting equation (7) to obtain the height of the inner layer high rib 3 of the envelope-formed thin-wall multilayer high rib component. Fig. 6 is a graph showing the change in the height of the inner-layer high ribs 2 and the height of the inner-layer high ribs 3 obtained by the above method.
Figure BDA0002965998970000073
Figure BDA0002965998970000074
Wherein H0Is the initial thickness H of the blank 60＝6mm，HtIs a final thickness H of the thin base plate 1t＝3mm。
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.

Claims (5)

1. A prediction method for space envelope metal flow and high-rib growth of a thin-wall multilayer high-rib component is characterized by comprising the following steps:
s1, decomposing the thin-wall multilayer high-rib component into a plurality of areas, wherein the area I is a thin baseplate area within the inner-layer high ribs, the area II is an inner-layer high rib area, the area III is a thin baseplate area between the inner-layer high ribs and the outer-layer high ribs, and the area IV is an outer-layer high rib area; dividing II into II areas by using the convergence plane as a boundaryAInner zone and IIBThe outer zone is divided into III zones by using the flow dividing surface as a boundaryAInner ring zone and IIIBAn outer annular zone;
s2, mixing IIBThe region abstraction is a corner extrusion model, and a deformation power method is adopted to derive IIBHorizontal pressing force q on the interface of zone and zone IIInObtaining qnSolving equation (1); abstracting the IV area into a corner extrusion model, and deducing the horizontal extrusion force q on the interface of the IV area and the III area by adopting a deformation power methodwObtaining qwSolving equation (2);
Figure FDA0002965998960000011
Figure FDA0002965998960000012
wherein H is the thickness of the thin bottom plate at any instant of envelope forming, r2Is the outer surface radius of the inner high rib, bwIs the thickness of the outer layer high rib, rpDividing the radius of the flow surface for enveloping any instant II, wherein K is the yield strength of the material, and m is the shear friction coefficient;
s3, abstracting the III area into a ring upsetting model with an inner cylindrical surface and an outer cylindrical surface bearing radial constraint loads, wherein the inner cylindrical surface radial constraint loads are q obtained in the step S2nThe outer cylindrical surface radial restraining load is q obtained in step S2w(ii) a Inner ring zone III by main stress methodAAnd the outer annular region IIIBRadial stress analysis is carried out to obtain IIIAZone radial stress σr_nDistribution equations (3) and IIIBZone radial stress σr_wDistribution equation (4);
Figure FDA0002965998960000013
Figure FDA0002965998960000021
wherein x is the radial distance from any position in zone III to the axis of the member, r3Is the radius of the inner surface of the outer high rib, rgFlow surface radius is distinguished for envelope forming at any instant III;
s4, according to two sides II of the inner-layer high-rib converging surfaceAZone and IIBIn the zone, the condition that the heights of the metals are required to be kept equal at any time of envelope forming is adopted, and a relation equation (5) of a flow dividing surface and a flow converging surface is established;
Figure FDA0002965998960000022
wherein r is1Is an inner layerThe radius of the inner surface of the high rib;
s5 according to the flow distribution surface rgIn a stress balance condition where the radial forces on the left and right sides are equal in magnitude, i.e.
Figure FDA0002965998960000025
Simultaneously satisfies the relation equation (5) of the flow dividing surface and the flow converging surface established in the step S4, and solves the position r of the flow dividing surface when the thickness of the thin bottom plate is H in the space envelope forming process of the thin-wall multilayer high-rib componentg(H)；
S6, the step S5 is executed to obtain rg(H) Substituting equation (6) to obtain the height of the inner layer high rib of the envelope-formed thin-wall multilayer high rib component; step S6 is performed to obtain rgSubstituting equation (7) to obtain the height of the outer layer high rib of the envelope-formed thin-wall multilayer high rib component;
Figure FDA0002965998960000023
Figure FDA0002965998960000024
wherein H0Is the initial thickness of the blank, HtIs the final thickness of the thin bottom plate.
2. The prediction method for the space envelope metal flow and the high-rib growth of the thin-wall multilayer high-rib component according to claim 1 is characterized in that the thin-wall multilayer high-rib component is manufactured by adopting a space envelope forming process, and a mold of the thin-wall multilayer high-rib component consists of an envelope convex mold and a concave mold; the bottom surface of the thin bottom plate and the outer surface of the outer layer high rib of the thin-wall multilayer high rib component are formed by a female die, the other molded surfaces are formed by an enveloping male die, the female die is required to be positioned below, and the enveloping male die is positioned above; the enveloping convex die is a conical die body, and rotates around the axis of the blank while rotating around the axis of the enveloping convex die, so that space enveloping motion is realized; the female die cavity is determined by the bottom surface of the thin bottom plate of the thin-wall multilayer high-rib component and the outer surface of the outer layer high-rib component, and the female die pushes the blank to move upwards along the axial direction; under the action of the axial motion of the female die and the space enveloping motion of the enveloping male die, the blank is subjected to plastic deformation, and the thin-wall multilayer high-rib component is gradually formed.
3. The prediction method for space-enveloped metal flow and high-tendon growth of the thin-wall multilayer high-tendon component according to claim 2, wherein the blank for space-enveloped formation of the thin-wall multilayer high-tendon component is a thick plate with uniform thickness, the axial cross-section shape of the thick plate is the same as that of the thin bottom plate, the blank is placed in the female die, the circumferential profile of the blank must be in contact with the side wall of the female die, and the bottom surface of the blank is in contact with the bottom surface of the female die.
4. The prediction method for the space-enveloped metal flow and the high-rib growth of the thin-wall multilayer high-rib component according to claim 3, characterized in that in the space-enveloped forming process of the thin-wall multilayer high-rib component, the contact area of an enveloping male die and a blank is not less than 75% of the upper surface area of the blank.
5. The prediction method for space-enveloped metal flow and high-rib growth of the thin-wall multi-layer high-rib component according to claim 1, characterized in that the cone angle alpha of the enveloping convex die is not less than 178 degrees.
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