CN114367734B - Optimized process method for friction stir processing modification of surface layer of self-adaptive plate - Google Patents
Optimized process method for friction stir processing modification of surface layer of self-adaptive plate Download PDFInfo
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Abstract
一种自适应板材表层搅拌摩擦加工改性的优化工艺方法，其特征是先基于实验，通过选用不同的材质、不同的钢材形状、尺寸等、不同的搅拌头结构、工艺参数、不同的改性路径、不同的改性方式等进行大量实验，获得各种板材试样进行性能测试，获得相关的实验结果，建立数据库，并通过有限元模拟与实验结合，拓展是呀结果数据库中的数据。基于结果数据库开发虚拟软件，分别从材质、板材形状、尺寸、客户需求入手，从数据库中找出对比，显示相关的试验数据传输到设备中进行实际加工，实现智能化、自适应加工改性优化方法，获得所需要的搅拌摩擦加工改性板材。本发明不仅节约成本，还能够精准的实现钢材表层改性，方法简单，便于实际推广应用。
An optimization process method for self-adaptive sheet surface friction stir processing modification, which is characterized in that based on experiments, by selecting different materials, different steel shapes, sizes, etc., different stirring head structures, process parameters, different modification A large number of experiments are carried out on paths, different modification methods, etc., various plate samples are obtained for performance testing, relevant experimental results are obtained, a database is established, and the data in the Yea results database is expanded through the combination of finite element simulation and experiments. Develop virtual software based on the result database, start with the material, plate shape, size, and customer demand, find out the comparison from the database, display the relevant test data and transfer it to the equipment for actual processing to achieve intelligent and adaptive processing modification optimization method to obtain the required friction stir processing modified plate. The invention not only saves the cost, but also can accurately realize the modification of the steel surface layer, and the method is simple and convenient for practical popularization and application.
Description
技术领域technical field
本发明涉及一种搅拌摩擦技术，尤其是一种搅拌摩擦改性技术，具体地说是一种自适应板材表层搅拌摩擦加工改性的优化工艺方法。The invention relates to a friction stir technology, in particular to a friction stir modification technology, in particular to an optimized process method for adaptive friction stir processing modification of the surface layer of a plate.
背景技术Background technique
在港口、矿山开采等一些恶劣环境下生产的设备由于长期处在腐蚀、高温、冲击等恶劣环境下，造成设备过早的出现报废。而在这些设备中应用最多的就是钢材，其在这种恶劣的环境下易于腐蚀、磨损，表面很快形成铁锈，且在盐雾等环境下进行腐蚀，钢材越来越薄，使用寿命也越来越短，造成设备故障率频繁发生。因此，不少类似的企业选用国外进口的特殊钢材进行设备制造，其成本之高，且这种进口钢材短期内国内无法自主生产，造成板材稀缺，造价增加，往往在某些性能方面得到体高，但生产成本的增加，也让这些生产企业最终放弃，造成企业成本大幅度的增加，利润降低，企业生存空间较小，严重的一些小型矿山企业出现倒闭现象。基于此类问题的出现，本发明专利通过大量的实验，集中力量选择不同的钢材、不同钢板形状尺寸等、不同的搅拌头结构、搅拌头工艺参数、搅拌头加工路径以及加工改性方式等进行大量实验，确定优化钢材搅拌摩擦改性加工方法，提升在国产钢材基础上实现钢材耐磨性和耐腐性等性能提高的有效工艺方法，以降低企业制造成本，提升企业利润为目的，强化企业基于普通钢材基础上实现特殊用途的钢材表层制备工艺方法，为工业技术发展提供一定的技术支持等。The equipment produced in some harsh environments such as ports and mines is exposed to harsh environments such as corrosion, high temperature, and impact for a long time, causing the equipment to be scrapped prematurely. Steel is the most widely used in these equipments. It is easy to corrode and wear in this harsh environment, and rust will quickly form on the surface, and it will corrode in salt spray and other environments. The thinner the steel, the longer the service life. Shorter and shorter, resulting in frequent occurrence of equipment failure rate. Therefore, many similar enterprises choose special steel imported from abroad for equipment manufacturing. The cost is high, and this kind of imported steel cannot be produced independently in China in a short period of time, resulting in scarcity of plates and increased cost. However, the increase in production costs also made these production enterprises finally give up, resulting in a substantial increase in enterprise costs, lower profits, less room for enterprise survival, and serious closures of some small mining enterprises. Based on the emergence of such problems, the patent of the present invention has focused on selecting different steel materials, different steel plate shapes and sizes, different agitating head structures, agitating head process parameters, agitating head processing paths, and processing modification methods through a large number of experiments. A large number of experiments have been carried out to determine and optimize the processing method of friction stir modification of steel, and to improve the effective process of improving the performance of steel such as wear resistance and corrosion resistance on the basis of domestic steel, so as to reduce the manufacturing cost of the enterprise and increase the profit of the enterprise. Based on ordinary steel, the steel surface preparation process for special purposes can be realized, and certain technical support can be provided for the development of industrial technology.
发明内容Contents of the invention
本发明的目的是针对现有的搅拌摩擦改性缺少最佳参数选择方法，造成改成过程中实际结构与理论预计差别较大，改性效果不理相的问题，发明一种自适应板材表层搅拌摩擦加工改性的优化工艺方法，它主要是先基于实验，通过选用不同的材质、不同的钢材形状、尺寸等、不同的搅拌头结构、工艺参数、不同的改性路径、不同的改性方式等进行大量实验，获得各种板材试样进行性能测试，获得相关的实验结果，建立数据库，并通过有限元模拟与实验结合，拓展是呀结果数据库中的数据。基于结果数据库开发虚拟软件，分别从材质、板材形状、尺寸、客户需求入手，从数据库中找出对比，显示相关的试验数据传输到设备中进行实际加工，实现智能化、自适应加工改性优化方法，获得所需要的搅拌摩擦加工改性板材。The purpose of the present invention is to solve the problem that the existing friction stir modification lacks the optimal parameter selection method, resulting in a large difference between the actual structure and the theoretical prediction in the modification process, and the modification effect is not reasonable, and to invent a self-adaptive plate surface layer The optimization process method of friction stir processing modification is mainly based on experiments first, through the selection of different materials, different steel shapes, sizes, etc., different stirring head structures, process parameters, different modification paths, and different modification methods. A large number of experiments are carried out by means of methods, etc., various plate samples are obtained for performance testing, relevant experimental results are obtained, a database is established, and the data in the result database is expanded through the combination of finite element simulation and experiment. Develop virtual software based on the result database, start with the material, plate shape, size, and customer needs, find out the comparison from the database, display the relevant test data and transmit it to the equipment for actual processing, and realize intelligent, adaptive processing, modification and optimization method to obtain the required friction stir processing modified plate.
本发明的技术方案是：Technical scheme of the present invention is:
一种自适应板材表层搅拌摩擦加工改性的优化工艺方法，其特征在于包括以下步骤：An optimized process method for friction stir processing modification of self-adaptive plate surface, characterized in that it comprises the following steps:
首先，建立搅拌摩擦加工改性实验前的相关参数数据库，通常应至少包括以下四个数据库：First of all, the relevant parameter database before the friction stir processing modification experiment should be established, which should usually include at least the following four databases:
（1）通过不同的分割方式建立各种材料的形状、尺寸结构库；(1) Establish the shape and size structure library of various materials through different segmentation methods;
（2）建立不同搅拌摩擦加工改性工艺参数库，其涉及搅拌头的轴肩大小、搅拌针的大小、搅拌头轴肩内部纹理结构、搅拌针上螺纹结构以及搅拌头制作材质，搅拌头旋转速度选择范围、搅拌头前进速度选择范围、搅拌头下压量规定范围、搅拌头倾斜角度规定范围及搅拌头正转和反转规定等；(2) Establish a database of different friction stir processing modification process parameters, which involves the size of the shaft shoulder of the stirring head, the size of the stirring pin, the internal texture structure of the stirring head shoulder, the thread structure of the stirring pin, and the material of the stirring head. The rotation of the stirring head The range of speed selection, the selection range of the forward speed of the stirring head, the specified range of the pressure of the stirring head, the specified range of the inclination angle of the stirring head, and the forward and reverse rotation of the stirring head, etc.;
（3）建立搅拌头加工路径方式库，其包括排列直线型、排列垂直型、从内到外型、从外到里型、以及从内到外圆形、从外到里圆形等；(3) Establish a library of processing paths for mixing heads, including linear arrangement, vertical arrangement, from inside to outside, from outside to inside, and from inside to outside circular, from outside to inside circular, etc.;
（4）建立加工改性方式库，此库包括直接通过搅拌头进行改性，不需要添加任何改性粉末；另外就是通过添加改性粉末，但这又涉及到不同的添加粉末方式，如钻孔添加粉末或直接开槽添加粉末，不论是孔和槽均有自己规定的相关参数，在此库中均要一一建立，在添加粉末改性的同时，还应确定添加粉末类型，确保获得不同性能的改性层，如纯粉末、混合粉末，其中混合粉末由包含了多种不同性能的混合粉末，以便库中可直接选择等。(4) Establish a library of processing modification methods. This library includes modification directly through the stirring head without adding any modified powder; the other is to add modified powder, but this involves different methods of adding powder, such as drilling Adding powder through holes or adding powder directly into slots, both holes and slots have their own regulated parameters, which must be established one by one in this library. While adding powder for modification, the type of added powder should also be determined to ensure that the obtained Modified layers with different properties, such as pure powder and mixed powder, where the mixed powder contains a variety of mixed powders with different properties, so that the library can be directly selected, etc.
其次，在上述4个库中选择不同的选项进行搅拌摩擦加工改性实验，获得不同的试验板材，在通过相关性能测试实验获得不同的试验结果进行建库，其中涉及到残余应力和变形的实验结果必须通过确定的数据进行观察分析，找出应力集中和变形特别严重的试样进行调整，调整要在调整方式库中选择不同的调整方式进行板材调整，再次通过检测，直至未出现明显的应力集中和变形，才将结果反馈到改性结果数据库中备用。Secondly, choose different options in the above four libraries to conduct friction stir processing modification experiments, obtain different test plates, and build the library after obtaining different test results through related performance test experiments, which involves residual stress and deformation experiments The results must be observed and analyzed through the determined data, and the samples with particularly serious stress concentration and deformation should be found out for adjustment. The adjustment should be adjusted by selecting different adjustment methods in the adjustment method library, and passing the test again until no obvious stress occurs. After concentration and deformation, the results are fed back to the modification result database for future use.
再次，通过实验获得结果是很有限的，必须通过有限元建立模型，通过模拟和实验相结合的方式拓展改性结果数据库的数据。通过建立模型，采用实验相同的工艺参数进行模拟，对比模拟和实验结果的差距，若比较接近，模型建立正确，可进行相关数据模拟并存入库中；若模拟与实验结果相差较大，要不断修正模型再次进行模拟并与实验结果对比，直至模拟和实验结果基本吻合，模拟相关数据进入改性结果数据库中，增加数据库中的数据。Thirdly, the results obtained through experiments are very limited, and the model must be established through finite elements, and the data in the database of modified results must be expanded through the combination of simulation and experiment. By establishing a model, use the same process parameters as the experiment to simulate, and compare the gap between the simulation and experimental results. If it is relatively close, the model is established correctly, and the relevant data can be simulated and stored in the database; The modified model is simulated again and compared with the experimental results until the simulation and experimental results are basically consistent, and the relevant simulation data are entered into the modification result database to increase the data in the database.
最后，基于前面的试验和模拟等结果建立的改性结果数据库，利用计算机软件进行自行匹配选择，即开发一款虚拟优化搅拌摩擦加工改性的软件，其界面主要涉及到改性板材材质、改性板材形状、客户性能要求、后台对比，显示板材分割模块、显示改性工艺参数选择信息等、显示搅拌头加工路径、显示加工改性方式、显示模拟结果、客户满意度等信息。在软件部分，由加工者在软件中直接输入加工改性的材质，并将客户要求输入到软件中，加工改性的设备在工作台上通过摄像头确定板材的形状并进行分割，最终在软件界面显示板材分割模块，软件后台根据所输入的改性材质、客户需求以及分割模块等确定改性相关的工艺参数，如搅拌头结构、尺寸、前进速度、旋转速度等，并显示在软件的界面上；另外根据改性结果数据库信息确定搅拌头加工路径、加工改性方式等信息并显示在软件界面上，待这些信息确定后，软件自行自动模拟，将模拟结果反馈到界面上，并通过内部顾客评价信息确定顾客满意度便于加工工人判断是否选择该优化加工改性方法进行改性，若可以，软件通过数据线将数据反射到搅拌摩擦加工改性装备上进行工件实际搅拌摩擦加工改性，获得最终的改性表层。Finally, based on the modification result database established by the previous test and simulation results, the computer software is used for self-matching selection, that is, a software for virtual optimization of friction stir processing modification is developed. Permanent plate shape, customer performance requirements, background comparison, display plate segmentation module, display modification process parameter selection information, etc., display mixing head processing path, display processing modification method, display simulation results, customer satisfaction and other information. In the software part, the processor directly inputs the processed and modified material into the software, and inputs the customer's requirements into the software. The processed and modified equipment determines the shape of the plate through the camera on the workbench and divides it, and finally displays it on the software interface. Display the plate segmentation module, the software background determines the process parameters related to modification according to the input modified material, customer demand and segmentation module, such as the structure, size, forward speed, rotation speed, etc. of the stirring head, and displays them on the software interface ; In addition, according to the modification result database information, determine the processing path of the mixing head, the processing modification method and other information and display them on the software interface. Evaluation information to determine customer satisfaction is convenient for processing workers to judge whether to choose the optimized processing modification method for modification. If possible, the software will reflect the data to the friction stir processing modification equipment through the data line to perform actual friction stir processing modification of the workpiece, and obtain The final modified surface.
本发明的有益效果：Beneficial effects of the present invention:
本发明采用的方法就是通过实验和模拟相结合的方式建立板材搅拌摩擦加工改性结果数据库，并基于数据库开发相应的软件对实际板材改性进行技术指导，通过软件模拟获得优化加工工艺方法，在传输到设备中实现实际加工工艺方法，获得实际的加工改性板材。本发明不仅节约成本，还能够精准的实现钢材表层改性，方法简单，便于实际推广应用。The method adopted in the present invention is to establish a plate material friction stir processing modification result database through a combination of experiment and simulation, and develop corresponding software based on the database to provide technical guidance for the actual plate material modification, and obtain an optimized processing method through software simulation. Transfer to the equipment to realize the actual processing method, and obtain the actual processed and modified plate. The invention not only saves the cost, but also can accurately realize the modification of the steel surface layer, the method is simple, and it is convenient for practical popularization and application.
附图说明Description of drawings
图1是本发明的技术流程图。Fig. 1 is a technical flow chart of the present invention.
具体实施方式Detailed ways
下面结合附图和实施例对本发明作进一步的说明。The present invention will be further described below in conjunction with the accompanying drawings and embodiments.
如图1所示。As shown in Figure 1.
一种自适应板材表层搅拌摩擦加工改性的优化工艺方法，它包括以下步骤：An optimized process method for friction stir processing modification of self-adaptive plate surface, which comprises the following steps:
首先，建立搅拌摩擦加工改性实验前的至少一列四个相关参数数据库：First, establish at least one column of four related parameter databases before the friction stir processing modification experiment:
（1）通过不同的分割方式建立各种材料的形状、尺寸结构库；(1) Establish the shape and size structure library of various materials through different segmentation methods;
（2）建立不同搅拌摩擦加工改性工艺参数库，其涉及搅拌头的轴肩大小、搅拌针的大小、搅拌头轴肩内部纹理结构、搅拌针上螺纹结构以及搅拌头制作材质，搅拌头旋转速度选择范围、搅拌头前进速度选择范围、搅拌头下压量规定范围、搅拌头倾斜角度规定范围及搅拌头正转和反转规定等；(2) Establish a database of different friction stir processing modification process parameters, which involves the size of the shaft shoulder of the stirring head, the size of the stirring pin, the internal texture structure of the stirring head shoulder, the thread structure of the stirring pin, and the material of the stirring head. The rotation of the stirring head The range of speed selection, the selection range of the forward speed of the stirring head, the specified range of the pressure of the stirring head, the specified range of the inclination angle of the stirring head, and the forward and reverse rotation of the stirring head, etc.;
（3）建立搅拌头加工路径方式库，其包括排列直线型、排列垂直型、从内到外型、从外到里型、以及从内到外圆形、从外到里圆形等；(3) Establish a library of processing paths for mixing heads, including linear arrangement, vertical arrangement, from inside to outside, from outside to inside, and from inside to outside circular, from outside to inside circular, etc.;
（4）建立加工改性方式库，此库包括直接通过搅拌头进行改性，不需要添加任何改性粉末；另外就是通过添加改性粉末，但这又涉及到不同的添加粉末方式，如钻孔添加粉末或直接开槽添加粉末，不论是孔和槽均有自己规定的相关参数，在此库中均要一一建立，在添加粉末改性的同时，还应确定添加粉末类型，确保获得不同性能的改性层，如纯粉末、混合粉末，其中混合粉末由包含了多种不同性能的混合粉末，以便库中可直接选择等。(4) Establish a library of processing modification methods. This library includes modification directly through the stirring head without adding any modified powder; the other is to add modified powder, but this involves different methods of adding powder, such as drilling Adding powder through holes or adding powder directly into slots, both holes and slots have their own regulated parameters, which must be established one by one in this library. While adding powder for modification, the type of added powder should also be determined to ensure that the obtained Modified layers with different properties, such as pure powder and mixed powder, where the mixed powder contains a variety of mixed powders with different properties, so that the library can be directly selected, etc.
其次，在上述四个库中选择不同的选项进行搅拌摩擦加工改性实验，获得不同的试验板材，在通过相关性能测试实验获得不同的试验结果进行建库，其中涉及到残余应力和变形的实验结果必须通过确定的数据进行观察分析，找出应力集中和变形特别严重的试样进行调整，调整要在调整方式库中选择不同的调整方式进行板材调整，再次通过检测，直至未出现明显的应力集中和变形，才将结果反馈到改性结果数据库中备用。Secondly, choose different options in the above four libraries to conduct friction stir processing modification experiments, obtain different test plates, and build the library after obtaining different test results through related performance test experiments, which involves residual stress and deformation experiments The results must be observed and analyzed through the determined data, and the samples with particularly serious stress concentration and deformation should be found out for adjustment. The adjustment should be adjusted by selecting different adjustment methods in the adjustment method library, and passing the test again until no obvious stress occurs. After concentration and deformation, the results are fed back to the modification result database for future use.
第三，由于通过实验获得结果是很有限的，因此可通过有限元建立模型，通过模拟和实验相结合的方式拓展改性结果数据库的数据。通过建立模型，采用实验相同的工艺参数进行模拟，对比模拟和实验结果的差距，若比较接近，模型建立正确，可进行相关数据模拟并存入库中；若模拟与实验结果相差较大，要不断修正模型再次进行模拟并与实验结果对比，直至模拟和实验结果基本吻合，模拟相关数据进入改性结果数据库中，增加数据库中的数据。Third, since the results obtained through experiments are very limited, the model can be established through finite elements, and the data of the modification result database can be expanded by combining simulation and experiment. By establishing a model, use the same process parameters as the experiment to simulate, and compare the gap between the simulation and experimental results. If it is relatively close, the model is established correctly, and the relevant data can be simulated and stored in the database; The modified model is simulated again and compared with the experimental results until the simulation and experimental results are basically consistent, and the relevant simulation data are entered into the modification result database to increase the data in the database.
最后，基于前面的试验和模拟等结果建立的改性结果数据库，并利用该数据库开发相应的软件（软件开发人员可通过现有技术加以实现），即开发一款虚拟优化搅拌摩擦加工改性的软件，其界面主要涉及到改性板材材质、改性板材形状、客户性能要求、后台对比，显示板材分割模块、显示改性工艺参数选择信息等、显示搅拌头加工路径、显示加工改性方式、显示模拟结果、客户满意度等信息。在软件部分，由加工者在软件中直接输入加工改性的材质，并将客户要求输入到软件中，加工改性的设备在工作台上通过摄像头确定板材的形状并进行分割，最终在软件界面显示板材分割模块，软件后台根据所输入的改性材质、客户需求以及分割模块等确定改性相关的工艺参数，如搅拌头结构、尺寸、前进速度、旋转速度等，并显示在软件的界面上；另外根据改性结果数据库信息确定搅拌头加工路径、加工改性方式等信息并显示在软件界面上，待这些信息确定后，软件自行自动模拟，将模拟结果反馈到界面上，并通过内部顾客评价信息确定顾客满意度便于加工工人判断是否选择该优化加工改性方法进行改性，若可以，软件通过数据线将数据反射到搅拌摩擦加工改性装备上进行工件实际搅拌摩擦加工改性，获得最终的改性表层，若不可以，则重新进行选择，直至获得满意的结果。Finally, based on the modification results database established based on the results of previous experiments and simulations, and using the database to develop corresponding software (software developers can implement it through existing technologies), that is, to develop a virtual optimized friction stir processing modification The interface of the software mainly involves the modified plate material, modified plate shape, customer performance requirements, background comparison, display plate segmentation module, display modification process parameter selection information, etc., display the processing path of the mixing head, display the processing modification method, Display simulation results, customer satisfaction, and more. In the software part, the processor directly inputs the processed and modified material into the software, and inputs the customer's requirements into the software. The processed and modified equipment determines the shape of the plate through the camera on the workbench and divides it, and finally displays it on the software interface. Display the plate segmentation module, the software background determines the process parameters related to modification according to the input modified material, customer demand and segmentation module, such as the structure, size, forward speed, rotation speed, etc. of the stirring head, and displays them on the software interface ; In addition, according to the modification result database information, determine the processing path of the mixing head, the processing modification method and other information and display them on the software interface. Evaluation information to determine customer satisfaction is convenient for processing workers to judge whether to choose the optimized processing modification method for modification. If possible, the software will reflect the data to the friction stir processing modification equipment through the data line to perform actual friction stir processing modification of the workpiece, and obtain If the final modified surface layer is not available, re-select until a satisfactory result is obtained.
本发明针对现有的板材类表层搅拌摩擦加工改性可以提高其耐磨性和耐腐蚀性等要求，在考虑到被改性的板材力学性能等相关要求的同时，尽可能的保证改性板材不出现大面积应力集中和变形，确保改性板材可以在适合的范围内进行应用。本发明正是基于此方面的考虑，从改性工艺参数、改性路径、加工改性方式等方面进行详细的建库，确保实验结果的严密性、可靠性，并通过改性板材进行相关性能测试，确保测试效果达到实际应用效果，在通过有限元模拟，增加改性结果数据库中的数据，便于建立软件，对实际工程应用提供理论指导，通过建立的软件进行工程模拟，并将模拟结果与实际装备相连，确定实际加工工艺方法，进行实际加工，获得所需要的改性板材等。本方法应用效果好、实用性强，可进行推广应用。The present invention aims at improving the wear resistance and corrosion resistance requirements of the existing board surface layer friction stir processing modification, while taking into account the related requirements such as the mechanical properties of the modified board, as much as possible to ensure the modification of the modified board. There is no large-area stress concentration and deformation, ensuring that the modified sheet can be applied within a suitable range. Based on this consideration, the present invention builds a database in detail from the aspects of modification process parameters, modification paths, processing and modification methods, etc., to ensure the rigor and reliability of the experimental results, and to carry out related performance tests through modified plates. Test to ensure that the test effect reaches the actual application effect. Through the finite element simulation, the data in the modification result database is increased to facilitate the establishment of software and provide theoretical guidance for actual engineering applications. The established software is used for engineering simulation, and the simulation results are compared with The actual equipment is connected, the actual processing method is determined, the actual processing is carried out, and the required modified plates are obtained. The method has good application effect and strong practicability, and can be popularized and applied.
本发明未涉及部分与现有技术相同或可采用现有技术加以实现。The parts not involved in the present invention are the same as the prior art or can be realized by adopting the prior art.
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