CN113591341A - Titanium alloy forging process optimization method based on numerical simulation - Google Patents
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- 238000000034 method Methods 0.000 title claims abstract description 88
- 238000005242 forging Methods 0.000 title claims abstract description 69
- 229910001069 Ti alloy Inorganic materials 0.000 title claims abstract description 41
- 238000004088 simulation Methods 0.000 title claims abstract description 25
- 238000005457 optimization Methods 0.000 title claims abstract description 19
- 230000008569 process Effects 0.000 claims abstract description 67
- 239000000463 material Substances 0.000 claims abstract description 52
- 238000001816 cooling Methods 0.000 claims abstract description 29
- 238000010438 heat treatment Methods 0.000 claims abstract description 21
- 238000009826 distribution Methods 0.000 claims abstract description 20
- 239000000956 alloy Substances 0.000 claims abstract description 12
- 238000001953 recrystallisation Methods 0.000 claims abstract description 9
- 239000002826 coolant Substances 0.000 claims abstract description 3
- 230000009467 reduction Effects 0.000 claims description 10
- 238000004364 calculation method Methods 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 238000004458 analytical method Methods 0.000 claims description 4
- 238000012546 transfer Methods 0.000 claims description 2
- 229910000883 Ti6Al4V Inorganic materials 0.000 description 7
- 239000000047 product Substances 0.000 description 6
- 239000013078 crystal Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
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- 238000005516 engineering process Methods 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
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- 238000012360 testing method Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
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- 238000002224 dissection Methods 0.000 description 1
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- 238000005265 energy consumption Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
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- 229910052742 iron Inorganic materials 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
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- 238000007517 polishing process Methods 0.000 description 1
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- 238000007670 refining Methods 0.000 description 1
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- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
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- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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- G—PHYSICS
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Abstract
The invention discloses a titanium alloy forging process optimization method based on numerical simulation, which considers the rheological behavior difference of a titanium alloy material under different temperatures and initial structure states, establishes constitutive equations of the titanium alloy material at different deformation stages, calculates the temperature field and stress field distribution of the material by using a finite element method according to the thermophysical performance parameters, recrystallization and grain growth kinetics of the material to be processed and the heat exchange coefficient of a cooling medium as initial conditions and boundary definition, and determines the heating, cooling and deformation parameters of the material, thereby realizing the optimization of the forging process. The method can quickly and effectively determine the heating and cooling time, the deformation rate, the deformation combination mode and the like in the titanium alloy forging process, improve the reasonability, the reliability and the economy in the process of making the process, and ensure the quality and the performance of products.
Description
Technical Field
The invention belongs to the technical field of titanium alloy processing, and particularly relates to a titanium alloy forging process optimization method based on numerical simulation.
Background
Titanium alloys have been widely used in the fields of aviation, aerospace, ships and medical treatment due to their characteristics of small density, high specific strength, good heat resistance, good low temperature performance, etc.
The traditional process is often based on experience or physical inspection determination of key parameters of the titanium alloy forging process. Experience often does not aim at specific materials, the overall dimensions of a forging stock and the like, and great randomness and deviation exist in the determination of forging parameters; and the material dissection analysis is required to be implemented through the material object inspection and determination, so that the efficiency is low and the cost is high. In addition, no standard process parameter setting criteria exist for blanks of different sizes.
Titanium alloy is a material which is very sensitive to temperature and strain, and is different from traditional metal materials, such as steel, and the theory of 'hot iron forging' exists since ancient times. For titanium alloy, because the heat conductivity is low, the temperature rise generated in the deformation process cannot be dissipated in time, the blank structure is over-burnt, and the defects of heat crack, abnormal structure and the like are generated, so that the temperature control titanium striking is proposed in engineering. And as the size of the billet increases, the non-uniformity of the deformation increases.
The heating, deformation and uniformity of the titanium alloy are affected by the temperature field and the strain field, which is shown in the following parameters need to be controlled in the forging process of the workpiece: heating temperature, deformation (upsetting and stretching), deformation rate (upsetting and stretching), and deformation mode (deformation combination mode). The parameter coupling effect influences the tissue evolution in the material deformation process, and further influences the form and mechanical property of the final tissue. This is an extremely complex process that is difficult to adequately master through a limited number of process trials.
The forging process numerical simulation technology can realize the prediction of the material heating, deformation and structure evolution process by means of a small amount of test tests, becomes an important auxiliary means in the research of metal hot working process, and is rapidly developed and widely applied in recent years.
In view of the above, the present inventors have studied and designed a titanium alloy forging process optimization method based on numerical simulation to solve the above technical problems.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a titanium alloy forging process optimization method based on numerical simulation, which is characterized in that an constitutive equation is established based on materials at different deformation stages, the temperature field and the strain field distribution of a blank are obtained by utilizing a finite element calculation method, the heating and cooling time is determined according to the size and the environmental condition of a forging blank, the temperature field, the strain field, recrystallization and the crystal grain distribution in the blank forging process are accurately predicted by utilizing a computer numerical simulation technology, and the key process parameters in the titanium alloy machining process can be rapidly and effectively determined by combining the forging blank forging combination mode design, so that the rationality and the reliability of process formulation and the stability of a process implementation process are improved.
The purpose of the invention is realized by the following technical scheme:
a titanium alloy forging process optimization method based on numerical simulation establishes constitutive equations of materials at different forging stages; according to thermophysical performance parameters of a material to be processed, recrystallization and grain growth kinetics and heat exchange coefficients of a cooling medium as initial conditions and boundary definitions, obtaining the temperature field and strain field distribution of a forging stock by using a finite element calculation method, and determining heating and cooling time and deformation parameters according to material sizes, thereby realizing the optimization of a forging process;
the thermophysical performance parameters comprise: density, heat transfer coefficient, specific heat capacity;
the recrystallization and grain growth kinetic parameters comprise: temperature, deformation amount, deformation rate and deformation combination mode.
Further, the finite element calculation method is realized by using, but not limited to, a finite element software Forge.
Further, on the basis of a Hansel-Spittel model, Forge software is adopted to describe the rheological behavior of the material under the conditions of different temperatures, different strain rates and different deformation amounts;
obtaining constitutive equations of the material in a single-phase region and a two-phase region:
constitutive equation of single-phase region material:
intrinsic equation of two-phase zone material:
further, the finite element calculation method obtains the temperature field and strain field distribution data of each part of the titanium alloy material in the forging process by carrying out numerical simulation analysis on the material heating process, the material cooling process, the upsetting process and the drawing process.
Further, in the cooling process, when the titanium alloy material is in the cogging and forming stage, the material is cooled by adopting a water cooling mode; when the product is close to the finished product stage, an air cooling mode is adopted to ensure the product quality.
Furthermore, in the upsetting process and the drawing process, the upsetting forging ratio is set to be 1.5-1.9; the upsetting speed is set to be 20 mm/s-60 mm/s; the drawing reduction is set between 80mm and 160 mm.
Furthermore, the upsetting and the drawing adopt a reversing mode.
Further, the single-fire deformation of the forging stock is not more than two upsetting and two drawing.
Compared with the prior art, the technical scheme provided by the invention has the following beneficial effects:
the titanium alloy forging process optimization method based on numerical simulation obtains the temperature field and strain field distribution of a titanium alloy (particularly Ti6Al4V) material in the heating and forging deformation processes by means of finite element simulation software and conventional experiments, quickly and effectively determines the heating, cooling and deformation parameters in the titanium alloy forging process, provides an optimization scheme, and improves the rationality, reliability and economy in the titanium alloy material forging process formulation process.
Drawings
FIG. 1 is a flow chart of a method for optimizing a titanium alloy forging process based on numerical simulation according to the present invention;
FIG. 2 is a graph showing the variation of the heat conductivity coefficient and the specific heat capacity of the Ti6Al4V alloy with temperature, which are calculated in the examples;
FIG. 3 is a graph of the relationship between the core temperature of the blank and the heating time and the furnace temperature in the example;
FIG. 4 is a graph of cooling pattern versus cooling time;
FIG. 5 is a graph showing the grain size distribution of the blank at different deformation rates in the example;
FIG. 6 is the cross-sectional strain profiles of the straight upset and reverse upset core of the billet in the examples.
Detailed Description
In order that the objects, aspects and advantages of the invention will become more apparent, the invention will be described by way of example only, and in connection with the accompanying drawings. It is to be understood that such description is merely illustrative and not restrictive of the scope of the invention. Moreover, in the following description, descriptions of well-known structures and techniques are omitted so as to not unnecessarily obscure the concepts of the present invention.
This example illustrates the process of cogging and forging a Ti6Al4V (TC4) titanium alloy ingot having a diameter of 920mm, which has a large initial cross-sectional dimension (greater than 621000 mm)2) The initial crystal grain is 200mm columnar crystal, and the final product is rectangular long section (the sectional area is smaller than 137000 mm)2) The length of the forged blank is more than 3300mm, the grain size is about 30 μm, the forged blank is spherical or short rod-shaped and is uniformly and discontinuously distributed, and the structure refinement and uniform deformation of the blank are realized and are difficult to realizeThe degree is relatively large. Determining and optimizing process parameters by numerical simulation, comprising the steps of:
step one, determining constitutive equation in thermal deformation process of material
In order to better describe the deformation process of the material, a Gleeble thermal compression test is adopted to obtain stress-strain data of the Ti6Al4V (TC4) titanium alloy material under different strains, different strain rates and different temperatures. And performing mathematical fitting treatment on the data, and describing a constitutive model of the material under the conditions of different temperatures, different strain rates and different deformation amounts based on a Hansel-Spittel model. Respectively obtain Ti6Al4V (TC4) titanium alloy materials in a single phase region (T is larger than)βtrans) And two phase region (< T)βtrans) The constitutive equation of (a) is as follows:
constitutive equation of single-phase region material:
intrinsic equation of two-phase zone material:
step two, determining the thermophysical property parameters of the material
Calculating various thermal physical performance parameters of the Ti6Al4V (TC4) titanium alloy material by using material thermodynamic calculation software JMatPro, wherein the parameters comprise density, heat conduction coefficient and specific heat capacity, and as the parameters are related to temperature, a curve of the actually calculated performance parameters and the temperature is shown in a relation graph of the calculated heat conduction coefficient and the specific heat capacity along with the change of the temperature in figure 2; the heat conduction coefficient and the radiation coefficient of the TC4 titanium alloy in the deformation process can be based on a large number of existing references, reasonable thermodynamic parameters can be reversely deduced according to actual production data to simulate in a limited mode, for example, the heat penetration time of heating a large number of materials with different specifications to different temperatures accumulated in production actually can be used, the forging blank heating process can be simulated by professional forging software Forge, the heat exchange coefficient is repeatedly taught, the simulation result is matched with the actual result, and therefore the heat exchange coefficient which is more in line with the actual situation can be obtained.
Step three, determining the relation of heating, cooling and deformation parameters and deformation modes to the temperature field, the strain field, the recrystallization and the grain distribution in the forging process
The method comprises the following steps of simulating by using a finite element calculation method, and carrying out numerical simulation analysis on the material heating process, the cooling process, the upsetting process and the drawing process to obtain the temperature field and strain field distribution data of each part of the material in the forging process, wherein the specific process comprises the following steps:
1) in the material heating process, the heat penetration time is influenced by the material size and the set temperature of the furnace, as shown in fig. 3, when the furnace temperature is close to the set temperature (within 10 ℃), the temperature is slowly increased and is difficult to reach the set value (lower than the set temperature by 1-3 ℃), and the high-temperature retention time in the heating process can be effectively shortened by properly increasing the set temperature;
2) in this embodiment, the forged intermediate billet is analyzed by water cooling or air cooling, as shown in fig. 4, the water cooling saves half of the cooling time compared with the air cooling under the same billet temperature condition, but the temperature gradient of each part of the material is larger under the water cooling condition, and larger residual stress is generated. In order to accelerate the production flow and refine the crystal grains, other fire times except the cogging and forming fire times can be cooled by adopting a water cooling mode;
3) in the upsetting process, the upsetting forging ratio influences the integral number of dynamic recrystallization crystals and the grain size of a forging stock, when the forging ratio is 1.5, the dynamic recrystallization of the heart of the forging stock presents obvious area distribution, the average grain size of the heart is 280-320 mu m, the average grain size of the heart of the forging stock is increased to 1.9 along with the forging ratio, the average grain size of the heart of the forging stock is 200-240 mu m, and the upsetting forging ratio is properly increased within the process allowable range, so that the improvement of the forging permeability of the stock and the grain size refinement are facilitated. As shown in FIG. 5, the upsetting rate affects the deformation resistance and the grain distribution, and when the upsetting rate is increased from 20mm/s to 60mm/s (the strain rate of the central section of the billet is 0.02 to 0.1 s)-1In the process), the deformation resistance peak stress of the material is increased from 1133 tons to 1341 tons, the forging energy consumption is increased, and the regionalization trend of the average grain size distribution is obvious; but do notWhen the deformation rate is changed within the range of 20-60 mm/s, the influence on the deformation uniformity of the material is not obvious, but the upsetting time is increased due to the excessively low upsetting rate;
4) in the drawing process, as shown in the following table one, the drawing draft affects the deformation uniformity and microstructure evolution of the billet. With the increase of the drawing reduction, the maximum value and the average value of the strain are continuously increased, the standard deviation of the strain is continuously increased, the uneven degree of deformation is aggravated, and the average grain size is reduced. Setting the deformation temperature to be 1100 ℃, the speed of a press to be 40mm/s and the blank with the initial grain size of 1000 mu m, wherein the blank can not be forged thoroughly when the single reduction is less than 40 mm; when the reduction is more than 160mm, the surface of the blank is subjected to folding damage at the interface of the anvil. The reduction is increased from 80mm to 160mm, so that the influence on the average grain size is not obvious, and therefore, within the process allowable range, the proper increase of the drawing reduction is beneficial to refining grains and improving the overall performance of the forging stock;
TABLE 1 strain field parameters and surface finish forging temperature of different rolling reduction stocks
It is noted that in the numerical simulation process of the present embodiment, the reversing upsetting is found to be beneficial to improve the deformation uniformity of the blank. Specifically, as shown in fig. 6, the reversing upsetting is beneficial to improving the deformation of the end of the blank, and compared with the straight upsetting, the reversing upsetting can reduce the standard deviation of strain distribution from 0.79 to 0.68, so that the deformation uniformity and the tissue uniformity are improved.
Finally, the condition that the fire frequency and the upsetting-drawing frequency influence the strain field and the temperature field distribution of the blank is verified, specific data are shown in the following table 2, the upsetting-drawing frequency completed in 1 fire influences the strain field and the temperature field distribution of the blank, the upsetting-drawing frequency is increased, and the nonuniformity of the strain field and the temperature field is increased. The surface temperature of the blank subjected to three-heading and three-drawing by one fire is reduced more, the strain and temperature distribution nonuniformity are maximum, the surface quality of the blank is poor, and a polishing process is required to be added; the forming quality of the three-fire finished three-heading and three-drawing surface is the best, the standard deviation of temperature and strain is the smallest, but the production efficiency is influenced by the heating times. The forging cost and the forming quality are comprehensively considered, and two upsetting and two drawing operations are selected to be completed every firing time.
TABLE 2 statistics of parameter values for different upsetting and drawing schemes
Step four, obtaining optimized forging process flow and process parameters
The embodiment is the forging process and parameter optimization of the thick large-section blank, the initial material of the embodiment is a large-specification Ti6Al4V cast ingot, and the target is a long and thin characteristic forging blank subjected to sufficient and uniform deformation. By the implementation, the following effects are obtained: 1. the heating and cooling processes of the titanium alloy material are influenced by the environment, different cooling modes influence the temperature field and the stress field distribution of the blank so as to influence the product quality, the residual stress can be released through the subsequent forging process in the titanium alloy cogging stage, the material is cooled by adopting a water cooling mode, the production flow and the grain refinement can be accelerated, and the air cooling mode is adopted in the finished product approaching stage so as to ensure the product quality; 2. the deformation and the deformation rate influence the deformation uniformity, the average grain size and the distribution of the material by influencing a temperature field and a strain field in the deformation process, when the upsetting forging ratio is 1.9, the average grain size of the center of the material is about 200-240 mu m, the upsetting forging ratio is properly increased in the process range, and the material forging permeability can be improved; the drawing reduction is between 80mm and 160mm, the average grain size is not changed greatly, and the drawing reduction can be properly improved so as to refine grains; the upsetting speed is 20-60 mm/s (the strain rate of the corresponding material center section is 0.02-1-0.1 s-1), so that the material can be deformed more uniformly; 3. the deformation mode and the deformation combination mode of the overall performance of the forging stock are improved, the deformation uniformity and the tissue uniformity of the stock are influenced, and the single-fire deformation is not more than two upsetting and two drawing.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several simple deductions or substitutions can be made without departing from the spirit of the invention, and all shall be considered as belonging to the protection scope of the invention.
Claims (8)
1. A titanium alloy forging process optimization method based on numerical simulation is characterized in that constitutive equations of materials at different forging stages are established; according to thermophysical performance parameters of a material to be processed, recrystallization and grain growth kinetics and heat exchange coefficients of a cooling medium as initial conditions and boundary definitions, obtaining the temperature field and strain field distribution of a forging stock by using a finite element calculation method, and determining heating and cooling time and deformation parameters according to material sizes, thereby realizing the optimization of a forging process;
the thermophysical performance parameters comprise: density, heat transfer coefficient, specific heat capacity;
the recrystallization and grain growth kinetic parameters comprise: temperature, deformation amount, deformation rate and deformation combination mode.
2. The titanium alloy forging process optimization method based on numerical simulation of claim 1, wherein the finite element calculation method is realized by using, but not limited to, a finite element software Forge.
3. The titanium alloy forging process optimization method based on numerical simulation of claim 1, wherein rheological behavior of the material under conditions of different temperatures, different strain rates and different deformation amounts is described by Forge software based on a Hansel-Spittel model;
obtaining constitutive equations of the material in a single-phase region and a two-phase region:
constitutive equation of single-phase region material:
intrinsic equation of two-phase zone material:
4. the method for optimizing the titanium alloy forging process based on the numerical simulation as claimed in claim 1, wherein the finite element calculation method is used for obtaining the temperature field and strain field distribution data of each part of the titanium alloy material in the forging process by carrying out numerical simulation analysis on the material heating process, the material cooling process, the upsetting process and the drawing process.
5. The titanium alloy forging process optimization method based on numerical simulation as claimed in claim 4, wherein in the cooling process, when the titanium alloy material is in the cogging and forming stage, the material is cooled in a water cooling mode; when the product is close to the finished product stage, an air cooling mode is adopted to ensure the product quality.
6. The method for optimizing the titanium alloy forging process based on the numerical simulation as claimed in claim 4, wherein in the upsetting process and the drawing process, the upsetting-forging ratio is set to 1.5-1.9; the upsetting speed is set to be 20 mm/s-60 mm/s; the drawing reduction is set between 80mm and 160 mm.
7. The titanium alloy forging process optimization method based on numerical simulation as claimed in claim 4, wherein upsetting and drawing are performed in a reversing manner.
8. The titanium alloy forging process optimization method based on numerical simulation of claim 4, wherein the single-heat deformation of the forging stock is not more than two upsetting and two drawing.
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