高精密阀套加工过程中的多工艺连续仿真分析及优化

Multi-process Continuous Simulation Analysis and Optimization ofHigh-precision Valve Sleeve in Machining Process

以航空燃油泵高精度渗氮分油活门阀套典型零件为例,采用多工艺连续仿真(CAE)与残余应力检测(XRD)相结合的方法,通过对毛坯轧制、正常化热处理、机械加工和渗氮4个工艺过程进行仿真模拟,并结合各工序的检测结果进行准确性验证,研究了工件在工艺过程中残余应力及变形的变化规律。结果表明,选择毛坯去除量小的热轧棒材作为阀套毛坯,可有效降低残余应力值的波动并减少其在后续渗氮工序中形成的累积;机械加工车削过程中,切进给量的影响大于切削速度,最优参数为进给0.06 mm、切削速度900 mm/s;去除喷砂工序且在渗氮前增加振动时效处理,渗氮前后的残余应力差值进一步降低,实际检测变形量为0.0070~0.0093 mm,小于公差要求的0.01 mm,变形量仿真值与实测值较为吻合。

Taking the typical components of the high-precision nitrogen-seepage oil distribution valve sleeve of the aviation fuel pump as an example,a combination method of multi-process continuous simulation(CAE)and residual stress detection(XRD)was used to simulate the four process processes of blank rolling,normalization heat treatment,mechanical processing and nitriding,and the accuracy was verified by combining the detection results of each process.The variation law of residual stress and deformation of the workpiece during the process was studied.The results indicated that selecting the hot-rolled bars with a small amount of blank removal as the valve sleeve blank could effectively reduce the fluctuation of residual stress values and reduce the accumulation formed during the subsequent nitriding process.In the mechanical machining turning process,the feed rate had a greater impact than that of cutting speed,with the optimal parameters being a feed rate of 0.06 mm and cutting speed of 900 mm/s.After removing the sandblasting process and addition of vibration aging treatment before nitriding,the difference in residual stress before and after nitriding was further reduced.The actual measured deformation was 0.0070 to 0.0093 mm,which was less than the tolerance requirement of 0.01 mm,and the simulated deformation value matched well with the measured value.