辊轮飞边槽开口角度对辊式成形筒体质量的影响

Influence of opening angle of roller flash groove on cylinder quality of roller forming

利用Pro-Engineer 3D构建了飞边槽开口角度为50°~110°的辊式成形模型,采用Deform-3D软件对辊式成形纯铝坯料的变形行为进行了有限元数值模拟。结果表明,当飞边槽开口角度从50°增大到110°时,飞边槽内金属变形均匀系数呈现先降低后升高的趋势;当飞边槽开口角度为50°时,产生的飞边最高,飞边槽内金属变形均匀系数最大,即变形最不均匀,第2道次整形后飞边处产生了折叠;随着飞边槽开口角度的增大,飞边的高度逐渐降低,第2道次整形后飞边处的折叠逐渐减少,飞边槽开口角度大于90°后折叠消失;当飞边槽开口角度为100°和110°时,由于飞边槽较宽,第2道次整形过程中部分金属流入整形辊轮飞边槽,造成整形后坯料壁厚不均匀。因此,飞边槽开口角度为90°左右时成形质量最好。

A roller forming model with flash groove opening angle of 50°-110°was established by Pro-Engineer 3D,and finite element numerical simulation of deformation behavior of pure aluminum billet in roller forming process was carried out by Deform-3D software.The results show that when the opening angle of flash groove increases from 50°to 110°,the uniformity coefficient of metal deformation in flash groove decreases at first and then increases.When the opening angle of flash groove is 50°,the flash is the highest,and the uniformity coefficient of metal deformation in the flash groove is the largest,which means the deformation is the most nonuniform,and the flashes are folded after the second pass shaping.With the increase of the opening angle of flash groove,the height of the flash is gradually reduced,and the fold of the flash is gradually reduced after the second pass shaping,and the fold disappears when the opening angle of the flash groove is larger than 90°.When the opening angle of flash groove is 100°and 110°,part of metal flows into the flash groove of the shaping roller due to the large width of the flash groove during the process of the second pass shaping,resulting in the uneven of wall thickness of the billet after shaping.Therefore,the forming quality is the best when the opening angle of flash groove is about 90°.