三通管液压成形技术有限元模拟及工艺分析

1、三通管液压成形技术有限元模拟及工艺分析-论文标题:三通管液压成形技术有限元模拟及工艺分析Finite Element Simulation and Technique Analysis of Tube Hydroforming Process论文作者 李乐论文导师 周杰,论文学位 硕士,论文专业 材料加工工程论文单位 重庆大学,点击次数 44,论文页数 68页File Size4673kT-shaped Tube; Hydroforming; FEM Simulation; Technology Analysis传统的塑性加工制造工艺普遍采用铸、锻、焊等工艺技术进行空心零件生产，从七十年代开始

2、出现了利用管坯塑性成形空心零件的技术。其中利用液压成形技术生产空心零件是目前较为先进的生产方法，该方法主要是利用专门的液压系统产生高达数百甚至上千MPa的成形压力最终使零件成形。由于液压成形方法的成形压力场分布均匀稳定，成形产品质量好，在冷成形中应用范围广，已成为塑性加工领域研究的前沿和热点，并在美、德、日、俄等国的科研机构和大型企业中得到了广泛应用。 三通管液压成形技术是该项技术中应用较为广泛的部分，同时也是一个难点。由于其成形过程中金属的变形行为非常复杂，理论分析困难，因此国内对于此问题的研究较少。本文针对目前科研和生产中的问题，使用有限元模拟仿真软件DYNAFORM结合液压技术对三通管液

3、压成形过程及工艺实施进行了研究。 本论文在综合查阅消化吸收大量国内外技术资料的基础上，对三通管液压成形方法进行了研究。首先分析研究三通管液压成形过程，比较该项工艺与传统成形工艺的不同特点，指出了影响三通管液压成形过程的主要因素，并研究了材料和管坯的成形性能对液压成形工艺的影响。其次，简要介绍了计算机仿真技术所依赖的有限元理论基础，并对板料成形专用有限元模拟仿真软件DYNAFORM的应用特点及功能做了总结和分析。然后，运用模拟仿真软件DYNAFORM分别分析了内压力、挤压力和平衡力对三通管成形的作用，明确了它们间的加载关系，并得出了最佳加载路径。之后，分析了凹模过渡区圆角半径，摩擦系数，管坯材料

4、以及管坯长径比等工艺参数对成形结果的影响，并得到了这些因素对三通管液压成形结果的基本影响规律。最后，通过对内高压液压技术的探讨，提出了产生内高压液压源的几种基本方法，针对三通管液压成形工艺的要求和特点，设计了成形模具装置和液压控制系统，并对液压技术实施中的密闭、介质、管接头以及润滑等工艺问题提出了基本解决方案。 本文对三通管液压成形技术的分析方法和得出的结论能够满足生产应用的基本要求，对于今后该项技术的进一步研究及推广应用将具有较为普遍的指导和参考意义。Generally the hollow parts have been producted by casting, forging and

5、welding in conventional plastic working and manufacturing engineering. From 70s, a new technology-the tube blank plastic forming, has emerged. Thereinto, the tube hydroforming is an advanced production method. Tube hydroforming is using special hydraulic to produce hundreds and even thousands MPa fo

6、rming pressure to make the parts forming. Because it"s forming pressure field distributes uniformity stabilization, the quality of product is high and the application field in cold forming is very wide, so this technology has been the new front and hot point in plastic working research, and so

7、on, it has been extensively used in scientific institutions and large enterprise in America, Germany, Japan and Russia.T-shaped tube hydroforming is applied abroad but it is a difficulty inthe tube hydroforming. Due to the excessively-large strain of the very complicated forming process, its analysi

8、s in theory is very difficult and the study about it is not popular in domestic. Aiming at the urgent needs of research and manufacture, this paper investigates the forming process and process engineering of T-shaped tube hydroforming with finite element simulation (FEM) software DYNAFORM and hydrau

9、lic.On the base of synthesis consult and digest absorb a great deal of overseas and domestic literature information, investigate the forming process of T-shaped tube hydroforming. First, analyse the hydroforming process and the forming rule, compare this method and the traditional technique, indicat

10、e the influences of the hydroforming process, and investigate the material and tube blank forming capability. Then, simply introduce the finite element theory foundation of computer simulation technology, analyse and sum up the application trait and function of the sheet forming simulation software-

11、DYNAFORM. Thirdly, by using the dynamic explicit finite element simulation software - DYNAFORM, analyse internal pressure, extrusion pressure and balance pressure , point out their loading relationship, and elicit optimal loading curve. Afterwards, analyse the radius , friction coefficient, material

12、s and the fineness-ratio of main duct, and elicit their infection disciplinarian curve. Lastly, discuss hyperpressure hydraulic, and present production ways of hydraulic pressure fountain. Aiming at the characteristic and request of T-shaped tube hydroforming, design the forming die andthe hydraulic control system. Present the solution project of the hermetic closure, pressure medium, pipe coupling and lubrication of the hydraulic.The anal