The bending section of tube between the bending die and the guider is in a less constrained state during the free bending process.The free bending dies have the important impact on the plastic deformation behavior and...The bending section of tube between the bending die and the guider is in a less constrained state during the free bending process.The free bending dies have the important impact on the plastic deformation behavior and the forming quality of tube.To study the evolution law of the deformation behavior of tube with the die structure parameters and optimize the free bending die parameters,the free bending experiments and the corresponding numerical simulations were carried out.The design principle of free bending die was illustrated.The free bending experiment was conducted to verify the reliability of the numerical simulation method.Based on the numerical simulation results,the influence of the distance between the center point of bending die and the front end of guider on the forming quality of bent tube is more obvious than that of the fillet of guider.However,the fillet of bending die hardly affects the stress and strain distribution and the evolution of the wall thickness.Finally,the free bending experiments with the newly determined free bending dies were conducted.The ultimate bending radius of bent tube is reduced and the forming quality is improved.展开更多
The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.T...The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.展开更多
Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forgin...Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forging is difficult to control. Many simulations and analysis of precision forging process were taken by previous researchers. But no concrete method is proposed to evaluate and optimize the forming quality of half axel gears. The primary purpose of this work is improving the forming quality of half axel gears by analyzing and optimizing the affected factors of forming quality. The enclosed-die warm forging process of half axle gears was developed, and a new type of die-set used on double action hydraulic press was brought forward. The main influential factors of precision forming quality were analyzed after the forming process had been simulated by using finite element method（FEM）. These factors include die structure, web thickness and web position. A method used to evaluate the forming quality was established, which investigated the maximal forming load, the metal filling rate and the material damage factor. The FEM simulations of half axle gears precision forging were evaluated by this method. The results show that the best forming quality can be achieved when the punches were added with bosses, the web located at the middle plant of the gear, and the web thickness was 30 percent of the inner hole diameter. Verification experiments taking the above optimized parameters were performed on a 7.8 MN double action hydraulic press. The trial products were formed well. And their geometric precision meets the demand. The verification result shows that the optimization of the influential factors, according to the simulations and the evaluation method, can improve the forming quality. The new structure of precision forging die-set and the new evaluation method guarantee a high forming quality ofhalfaxel gears.展开更多
The 4-lobe aluminum alloy helical surface rotors are widely applied in industry,such as superchargers.Generally,the conventional manufacturing processes of aluminum alloy helical surface are time consuming and costly....The 4-lobe aluminum alloy helical surface rotors are widely applied in industry,such as superchargers.Generally,the conventional manufacturing processes of aluminum alloy helical surface are time consuming and costly.To make the manufacturing processes more flexible and economical,the forward hot extrusion process is proposed to form the 4-lobe aluminum alloy helical surface rotors.In this work,we implement both simulations and experiments to the forming process of the helical surface,of which the material is 6063 aluminum alloy.The forward hot extrusion process is simulated with finite element method in DEFORM-3D.Based on the simulation method,the influences of different extrusion parameters,such as extrusion temperature,extrusion speed and extrusion ratio,on the extrusion process are studied.According to the numerical simulation results,the optimal case is chosen to carry out the experiment.Furthermore,the experimental results show that the surface is smooth;the toothed fill is full;the twist angle in the length direction is evenly distributed;the value of twist angle is roughly in line with the design angle,which is mainly due to the modified die structure,having a positive and significant effect on the increment of twist angle.Therefore,the twist angle has an increase of about 76%,which verifies the modified die structure.展开更多
基金The investigation was supported from the Opening Project of State Key Lab of Digital Manufacturing Equipment&Technology(No.DMETKF2021004)the National Natural Science Foundation of China(Nos.52105360,U1937206,and 52175328)+1 种基金2021 Jiangsu Shuangchuang Talent Program(JSSCBS20210157)Fundamental Research Funds for the Central Universities(No.NS2022061).
文摘The bending section of tube between the bending die and the guider is in a less constrained state during the free bending process.The free bending dies have the important impact on the plastic deformation behavior and the forming quality of tube.To study the evolution law of the deformation behavior of tube with the die structure parameters and optimize the free bending die parameters,the free bending experiments and the corresponding numerical simulations were carried out.The design principle of free bending die was illustrated.The free bending experiment was conducted to verify the reliability of the numerical simulation method.Based on the numerical simulation results,the influence of the distance between the center point of bending die and the front end of guider on the forming quality of bent tube is more obvious than that of the fillet of guider.However,the fillet of bending die hardly affects the stress and strain distribution and the evolution of the wall thickness.Finally,the free bending experiments with the newly determined free bending dies were conducted.The ultimate bending radius of bent tube is reduced and the forming quality is improved.
基金Founded by the National Key Technology R&D Program in the 11th Five Year Plan of China(2007BAE38B00)
文摘The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.
基金supported by Chongqing Municipal Science and Technology Committee of China (Grant No. 2005AA3012-4)
文摘Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forging is difficult to control. Many simulations and analysis of precision forging process were taken by previous researchers. But no concrete method is proposed to evaluate and optimize the forming quality of half axel gears. The primary purpose of this work is improving the forming quality of half axel gears by analyzing and optimizing the affected factors of forming quality. The enclosed-die warm forging process of half axle gears was developed, and a new type of die-set used on double action hydraulic press was brought forward. The main influential factors of precision forming quality were analyzed after the forming process had been simulated by using finite element method（FEM）. These factors include die structure, web thickness and web position. A method used to evaluate the forming quality was established, which investigated the maximal forming load, the metal filling rate and the material damage factor. The FEM simulations of half axle gears precision forging were evaluated by this method. The results show that the best forming quality can be achieved when the punches were added with bosses, the web located at the middle plant of the gear, and the web thickness was 30 percent of the inner hole diameter. Verification experiments taking the above optimized parameters were performed on a 7.8 MN double action hydraulic press. The trial products were formed well. And their geometric precision meets the demand. The verification result shows that the optimization of the influential factors, according to the simulations and the evaluation method, can improve the forming quality. The new structure of precision forging die-set and the new evaluation method guarantee a high forming quality ofhalfaxel gears.
基金Project(zzyjkt2014-09)supported by the National Key Laboratory of High Performance and Complex Manufacturing,ChinaProject(2015GK3006)supported by Key R&D Program of Science and Technology Department of Hunan Province,China
文摘The 4-lobe aluminum alloy helical surface rotors are widely applied in industry,such as superchargers.Generally,the conventional manufacturing processes of aluminum alloy helical surface are time consuming and costly.To make the manufacturing processes more flexible and economical,the forward hot extrusion process is proposed to form the 4-lobe aluminum alloy helical surface rotors.In this work,we implement both simulations and experiments to the forming process of the helical surface,of which the material is 6063 aluminum alloy.The forward hot extrusion process is simulated with finite element method in DEFORM-3D.Based on the simulation method,the influences of different extrusion parameters,such as extrusion temperature,extrusion speed and extrusion ratio,on the extrusion process are studied.According to the numerical simulation results,the optimal case is chosen to carry out the experiment.Furthermore,the experimental results show that the surface is smooth;the toothed fill is full;the twist angle in the length direction is evenly distributed;the value of twist angle is roughly in line with the design angle,which is mainly due to the modified die structure,having a positive and significant effect on the increment of twist angle.Therefore,the twist angle has an increase of about 76%,which verifies the modified die structure.
