Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂ca...Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂casting-rolling compound forming technology＂ is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.展开更多
By using the Finite Element Inverse Approach based on the Hill quadratic anisotrop-ically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The ...By using the Finite Element Inverse Approach based on the Hill quadratic anisotrop-ically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The blank shapes of three typical stampings are simulated and compared with numerical results given by the AUTOFORM software and experimental results, respectively. The comparison shows that the FASTAMP can predict blank shape and strain distribution of the stamping more precisely and quickly than those given by the traditional methods and the AUTOFORM.展开更多
Viscous pressure forming (VPF), is suitable for forming difficult to form sheet metal parts. An investigation in the effect of blank holder pressure (BHP) on VPF aluminum alloy ladder parts was conducted. Based on exp...Viscous pressure forming (VPF), is suitable for forming difficult to form sheet metal parts. An investigation in the effect of blank holder pressure (BHP) on VPF aluminum alloy ladder parts was conducted. Based on experimental and numerical simulation results of the effect of BHP on dimensional accuracy, wall thickness reduction, forming pressure, material flow and defects (such as wrinkling and fracture) of specimens, the effect patterns of BHP load path on VPF ladder parts were explained. The limits of BHP corresponding to specimens with no defect and with wrinkling or fracture defect were determined. In the limits of formable BHP, the variable load path of BHP was beneficial to drawing blank into the die and decreasing wall thickness reduction of specimens. The experimental results show that the ladder parts of good surface fineness and high dimensional accuracy can be obtained by variable load paths of BHP.展开更多
The forming defects, including thinning, rupture, wrinkling and springback, usually arising in producing a side-door impact beam, were investigated by trial and numerical simulation. A temperature-related constitutive...The forming defects, including thinning, rupture, wrinkling and springback, usually arising in producing a side-door impact beam, were investigated by trial and numerical simulation. A temperature-related constitutive model specific to the temperature range from 350 °C to 500 °C was established and used for the numerical simulation. The trial and numerical simulation were conducted to clarify the quantitative characteristics of forming defects and to analyze the effects of process parameters on the forming defects. Results show that the rupture situation is ameliorated and the springback is eliminated in the aluminum alloy hot stamping. The wrinkling severity decreases with increasing blank holder force (BHF), but the BHF greater than 15 kN causes the rupture at the deepest drawing position of workpiece. The forming defects are avoided with lubricant in the feasible ranges of process parameters: the BHF of 3 to 5 kN and the stamping speed of 50 to 200 mm/s.展开更多
Based on the elastoplastic mechanical properties of the weld and heat affected zone metals obtained by a nanoindentation test, a theoretical calculation model was established for the forming limit diagram（FLD） of ta...Based on the elastoplastic mechanical properties of the weld and heat affected zone metals obtained by a nanoindentation test, a theoretical calculation model was established for the forming limit diagram（FLD） of tailor-welded blanks（TWBs） on the basis of plastic constitutive relations and Hosford yield criteria. Hemispherical punch bulging tests were performed to verify the FLD theoretical calculation results. The results demonstrated that not only the FLD theoretical calculation of base materials but also that of TWBs had a good agreement with their experiments. Besides, poorer formability of TWBs caused its FLD significantly lower than that of base materials. The theoretical calculation model offers a reliable approach to obtain the specific FLD of TWBs.展开更多
Electromagnetic V-shape bending of small size sheet blank is investigated numerically and experimentally. Three-dimensional electromagnetic field models are established to calculate the magnetic force distribution on ...Electromagnetic V-shape bending of small size sheet blank is investigated numerically and experimentally. Three-dimensional electromagnetic field models are established to calculate the magnetic force distribution on the sheet by software ANSYS / EMAG. Series of electromagnetic V-shape bending forming experiments are presented,in which small size uniform pressure coil and big size round flat spiral coil are used. The results show that small size uniform pressure coil is not suitable for electromagnetic forming of small size flat sheet,and the coil is susceptible to failure such as bulging,ablation and cracking. When the plane dimension of round flat spiral coil is bigger than sheet blank sizes,the induced current crowding effect will be resulted which seriously influence the magnetic force distribution on the sheet. In this case,magnetic force distribution can be adjusted through the change of the relative position between coil and sheet,the desired deformation can be obtained finally. Therefore,big size round flat spiral coil can be well applied to electromagnetic V-shape bending forming of small size flat sheet.展开更多
The final quality of complex conical-section rings depends on co-design of multiple processes in forming process chain.In this study,for a complex aeroengine casing ring with a large slope and a flange on its end,a co...The final quality of complex conical-section rings depends on co-design of multiple processes in forming process chain.In this study,for a complex aeroengine casing ring with a large slope and a flange on its end,a co-design method of the forming process chain is put forward towards the objective of precision forming,which not only proposes a standard process route composed of multiple processes of upsetting,punching,rectangular ring rolling,loose tooling forging and profiled ring rolling,but also presents co-design methods of dies and blanks for all the processes.For profiled ring rolling,a design method of preformed blank that makes the blank and the target conical-section ring have the same axial volume distribution is proposed.By the method,the axial metal redistribution during the process can be alleviated greatly thus improving the forming stability and precision of the ring.Based on the geometric features of designed preformed blank,design methods of blanks and dies for loose tolling forging,rectangular ring rolling,punching and upsetting are proposed sequentially.In view of the key roles of loose tooling forging(manufacturing the preformed blank)and profiled ring rolling on the final quality of the conical ring parts,inherited FE simulations for these two processes are performed to verify the proposed design methods and determine appropriate design parameter.It is demonstrated that the proposed design method has significant advantages in improving forming precision.Besides,a suggestive value 1.5 of the rolling ratio for profiled ring rolling(a key design parameter)is given based on comprehensive consideration of multiple indicators such as ring roundness,deformation uniformity and forming load.The corresponding industrial experiments performed illustrate that a high forming precision of the conical-section aeroengine casing ring is achieved.展开更多
Teflon-pad shaping process of circular metal blanks into quasi-cup specimens is investigated by theoretical and experimental methods in the quasi-static condition. In the experiments, circular metal sheets are formed ...Teflon-pad shaping process of circular metal blanks into quasi-cup specimens is investigated by theoretical and experimental methods in the quasi-static condition. In the experiments, circular metal sheets are formed into the quasi-cup samples by compressing them between a Teflon-filled die and a rigid punch with desirable shape. To investigate influences of different parameters on the forming progress, 12 rigid punches with different dimensions, two blank material types of aluminum and galvanized iron, three blank thicknesses of 0.6, 1.1 and 1.5 mm, and two Teflon-fillers of PVC and polyurethane are used in several experimental tests. In the analytical part, theoretical deformation models of metal blank and Teflon-filler are introduced and based on energy method, energy absorptions by the blank and Teflon-filler are calculated to derive a theoretical formula for predicting total required energy of the forming process. For this purpose, several energy absorption mechanisms are considered in the blank and filler. Furthermore, predictions by theoretical equation are compared with the corresponding experimental tests to study the verity of the calculated formulas. Theoretical and experimental results illustrate change trend of forming energy with respect to blank thickness. Also, the performed forming tests show that when external cone angle of rigid punch with respect to the horizontal direction increases, forming energy increases nonlinearly; and when the depth of spherical part of rigid punch increases, the probability of rupture increases. Additionally, the experiments demonstrate that there is a direct relationship between the forming energy and flow stress of the blanks. Furthermore, experimental observations illustrate that forming energy of a certain blank with PVC Teflon-filler is higher than that of a similar specimen with polyurethane Teflon-filler; but, the probability of wrinkling decreases when PVC Teflon-pad is used as the filler; and it is advantage of PVC Teflon-filler with respect to polyurethane Teflon.展开更多
基金supported by Key Program of National Natural Science Foundation of China(Grant No.51135007)National Natural Science Foundation of China(Grant No.51075290)
文摘Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named ＂casting-rolling compound forming technology＂ is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.
基金Project supported by the National Natural Sciences Foundation of China(No. 50335060).
文摘By using the Finite Element Inverse Approach based on the Hill quadratic anisotrop-ically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The blank shapes of three typical stampings are simulated and compared with numerical results given by the AUTOFORM software and experimental results, respectively. The comparison shows that the FASTAMP can predict blank shape and strain distribution of the stamping more precisely and quickly than those given by the traditional methods and the AUTOFORM.
文摘Viscous pressure forming (VPF), is suitable for forming difficult to form sheet metal parts. An investigation in the effect of blank holder pressure (BHP) on VPF aluminum alloy ladder parts was conducted. Based on experimental and numerical simulation results of the effect of BHP on dimensional accuracy, wall thickness reduction, forming pressure, material flow and defects (such as wrinkling and fracture) of specimens, the effect patterns of BHP load path on VPF ladder parts were explained. The limits of BHP corresponding to specimens with no defect and with wrinkling or fracture defect were determined. In the limits of formable BHP, the variable load path of BHP was beneficial to drawing blank into the die and decreasing wall thickness reduction of specimens. The experimental results show that the ladder parts of good surface fineness and high dimensional accuracy can be obtained by variable load paths of BHP.
基金Project(P2014-15)supported by the State Key Laboratory of Materials Processing and Die&Mould Technology,Huazhong University of Science and Technology,ChinaProject supported by the Beijing Laboratory of Metallic Materials and Processing for Modern Transportation,China
文摘The forming defects, including thinning, rupture, wrinkling and springback, usually arising in producing a side-door impact beam, were investigated by trial and numerical simulation. A temperature-related constitutive model specific to the temperature range from 350 °C to 500 °C was established and used for the numerical simulation. The trial and numerical simulation were conducted to clarify the quantitative characteristics of forming defects and to analyze the effects of process parameters on the forming defects. Results show that the rupture situation is ameliorated and the springback is eliminated in the aluminum alloy hot stamping. The wrinkling severity decreases with increasing blank holder force (BHF), but the BHF greater than 15 kN causes the rupture at the deepest drawing position of workpiece. The forming defects are avoided with lubricant in the feasible ranges of process parameters: the BHF of 3 to 5 kN and the stamping speed of 50 to 200 mm/s.
基金Project(51275444) supported by the National Natural Science Foundation of ChinaProject(20121333110003) supported by the Specialized Research Fund for the Doctoral Program of Higher Education,China+1 种基金Project(E2014203271) supported by the Natural Science Foundation–Steel and Iron Foundation of Hebei ProvinceChina
文摘Based on the elastoplastic mechanical properties of the weld and heat affected zone metals obtained by a nanoindentation test, a theoretical calculation model was established for the forming limit diagram（FLD） of tailor-welded blanks（TWBs） on the basis of plastic constitutive relations and Hosford yield criteria. Hemispherical punch bulging tests were performed to verify the FLD theoretical calculation results. The results demonstrated that not only the FLD theoretical calculation of base materials but also that of TWBs had a good agreement with their experiments. Besides, poorer formability of TWBs caused its FLD significantly lower than that of base materials. The theoretical calculation model offers a reliable approach to obtain the specific FLD of TWBs.
基金Sponsored by the National Basic Research Program of China(Grant No.2011CB012800 and 2011CB012804)
文摘Electromagnetic V-shape bending of small size sheet blank is investigated numerically and experimentally. Three-dimensional electromagnetic field models are established to calculate the magnetic force distribution on the sheet by software ANSYS / EMAG. Series of electromagnetic V-shape bending forming experiments are presented,in which small size uniform pressure coil and big size round flat spiral coil are used. The results show that small size uniform pressure coil is not suitable for electromagnetic forming of small size flat sheet,and the coil is susceptible to failure such as bulging,ablation and cracking. When the plane dimension of round flat spiral coil is bigger than sheet blank sizes,the induced current crowding effect will be resulted which seriously influence the magnetic force distribution on the sheet. In this case,magnetic force distribution can be adjusted through the change of the relative position between coil and sheet,the desired deformation can be obtained finally. Therefore,big size round flat spiral coil can be well applied to electromagnetic V-shape bending forming of small size flat sheet.
基金the National Natural Science Foundation of China(52275378).
文摘The final quality of complex conical-section rings depends on co-design of multiple processes in forming process chain.In this study,for a complex aeroengine casing ring with a large slope and a flange on its end,a co-design method of the forming process chain is put forward towards the objective of precision forming,which not only proposes a standard process route composed of multiple processes of upsetting,punching,rectangular ring rolling,loose tooling forging and profiled ring rolling,but also presents co-design methods of dies and blanks for all the processes.For profiled ring rolling,a design method of preformed blank that makes the blank and the target conical-section ring have the same axial volume distribution is proposed.By the method,the axial metal redistribution during the process can be alleviated greatly thus improving the forming stability and precision of the ring.Based on the geometric features of designed preformed blank,design methods of blanks and dies for loose tolling forging,rectangular ring rolling,punching and upsetting are proposed sequentially.In view of the key roles of loose tooling forging(manufacturing the preformed blank)and profiled ring rolling on the final quality of the conical ring parts,inherited FE simulations for these two processes are performed to verify the proposed design methods and determine appropriate design parameter.It is demonstrated that the proposed design method has significant advantages in improving forming precision.Besides,a suggestive value 1.5 of the rolling ratio for profiled ring rolling(a key design parameter)is given based on comprehensive consideration of multiple indicators such as ring roundness,deformation uniformity and forming load.The corresponding industrial experiments performed illustrate that a high forming precision of the conical-section aeroengine casing ring is achieved.
文摘Teflon-pad shaping process of circular metal blanks into quasi-cup specimens is investigated by theoretical and experimental methods in the quasi-static condition. In the experiments, circular metal sheets are formed into the quasi-cup samples by compressing them between a Teflon-filled die and a rigid punch with desirable shape. To investigate influences of different parameters on the forming progress, 12 rigid punches with different dimensions, two blank material types of aluminum and galvanized iron, three blank thicknesses of 0.6, 1.1 and 1.5 mm, and two Teflon-fillers of PVC and polyurethane are used in several experimental tests. In the analytical part, theoretical deformation models of metal blank and Teflon-filler are introduced and based on energy method, energy absorptions by the blank and Teflon-filler are calculated to derive a theoretical formula for predicting total required energy of the forming process. For this purpose, several energy absorption mechanisms are considered in the blank and filler. Furthermore, predictions by theoretical equation are compared with the corresponding experimental tests to study the verity of the calculated formulas. Theoretical and experimental results illustrate change trend of forming energy with respect to blank thickness. Also, the performed forming tests show that when external cone angle of rigid punch with respect to the horizontal direction increases, forming energy increases nonlinearly; and when the depth of spherical part of rigid punch increases, the probability of rupture increases. Additionally, the experiments demonstrate that there is a direct relationship between the forming energy and flow stress of the blanks. Furthermore, experimental observations illustrate that forming energy of a certain blank with PVC Teflon-filler is higher than that of a similar specimen with polyurethane Teflon-filler; but, the probability of wrinkling decreases when PVC Teflon-pad is used as the filler; and it is advantage of PVC Teflon-filler with respect to polyurethane Teflon.
