矩形钢丝成形有限元模拟及工艺参数优化

Finite-element simulation of rectangular wire shape and optimization of process parameters

矩形钢丝截面由直边与圆角组成,模拉时直边与圆角处的磨损不均匀,模具寿命很低。提出组合法矩形钢丝成形工艺,建立组合法矩形钢丝成形过程的有限元模型,采用古布金公式验证有限元模型的正确性。利用正交试验法对工作锥角、定径带长度、圆角半径、摩擦因数和拉拔速度等工艺参数进行优化,得到直径4.2 mm的Q195钢丝,用组合法拉拔成截面为2.3 mm×4.8 mm的矩形钢丝最优工艺参数组合:工作锥角为14,°定径带长度为3.2 mm,圆角半径为0.7 mm,摩擦因数为0.12,拉拔速度为1.2 m/s。

The cross-section of rectangular wire is composed of lines and arcs. The wear of rectangular die in the lines and arcs is nonhomogeneous, so the service life of die is short. Combined method rectangular wire forming process was put forward, the finite element model of combined method rectangular wire forming process was established. The validity of finite element model was confirmed by adopting GubKin＇s formula. Process parameters such as working cone angle, bearing length, radius of are, friction coefficient, drawing speed and so on were optimized by adopting orthogonal experiment meth- od. When diameter 4.2 mm Q195 steel wire was drawn to cross-section 2.3 mm × 4.8 mm rectangular wire by adopting combined method, the conclusion of optimal process parameters was drawn as follows： working cone angle 14 degree, bearing length 3.2 mm, radius of arc 0.7 mm, friction coefficient 0.12 and drawing speed 1.2 m/s.