铜/铝复合管三辊斜轧的结合过程模拟与实验验证

侯文静; 陈鹏; 牛辉; 付伦; 和东平; 王涛

doi:10.3969/j.issn.1674-6457.2025.11.006

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (11) : 68-78. DOI: 10.3969/j.issn.1674-6457.2025.11.006

先进材料智能成形技术

铜/铝复合管三辊斜轧的结合过程模拟与实验验证

侯文静^1,2, 陈鹏^1,2, 牛辉^1,2,*, 付伦^1,2, 和东平^1,2, 王涛^1,2

作者信息 +

Simulation and Experimental Verification of the Bonding Process in Three-roll Skew Rolling of Cu/Al Composite Tubes

HOU Wenjing^1,2, CHEN Peng^1,2, NIU Hui^1,2,*, FU Lun^1,2, HE Dongping^1,2, WANG Tao^1,2

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文章历史 +

摘要

目的探究铜/铝复合管三辊斜轧动态成形过程与界面结合规律。方法基于ABAQUS软件建立了铜/铝复合管三辊斜轧的动态复合有限元模型,并采用VUINTER子程序描述异种金属界面的接触关系,基于此分析了轧制过程中的界面结合演化及金属变形规律。进行了温度为400 ℃、压下量为25%的铜/铝复合管三辊斜轧实验,通过轧后复合管宏观尺寸验证了有限元模型的可靠性,并基于拉剪实验和微观表征手段分析了异种金属结合界面的宏微观特征。结果仿真分析结果表明,所建立的模型能够模拟铜/铝界面的“变形-结合-成形”动态过程,复合管在三辊斜轧中呈螺旋前进,径向界面经历“圆形-三角形-圆形”的变形过程,且该变形过程与应力场“上升-稳定-回落”、速度场“梯度-同步-差异”、界面结合率“迟滞启动-快速增长-稳定饱和”三阶段变化对应。实验结果表明,制备的复合管宏观形貌完整,界面平直连续,宏观尺寸（直径、长度等）与有限元模拟结果误差不超过5%,有效证明了仿真分析的可靠性。此外,实验分析结果表明,复合管界面拉剪强度约为69.97 MPa,断裂位于铝基体且呈韧性断裂,结合界面处形成了约1.5 μm元素扩散层,实现了冶金结合。结论所建立的三辊斜轧有限元模型成功模拟了铜/铝复合管动态复合过程,并揭示了金属结合界面在成形过程中场变量的演化规律,可为双金属复合管三辊斜轧工艺研究提供理论指导。

Abstract

The work aims to investigate the dynamic forming process and interfacial bonding behavior of Cu/Al composite tubes during three-roll skew rolling. A finite element model was developed with ABAQUS and a VUINTER subroutine was employed to describe the contact interaction between dissimilar metals. Based on this, the evolution of interfacial bonding and metal deformation during rolling were analyzed. Three-roll skew rolling experiments were conducted on Cu/Al composite tubes under conditions of 400 ℃ and 25% reduction. The reliability of the finite element model was verified by comparing the macroscopic dimensions of the rolled tubes with simulation results. The macro and micro characteristics of the bonding interface were further examined through shear tests and microstructural analysis. The simulation results showed that the established model effectively captured the dynamic "deformation-bonding-forming" process at the Cu/Al interface. The composite tubes advanced spirally during three-roll cross wedge rolling, with their radial cross-section undergoing a "circular-triangular-circular" deformation process, and this deformation process corresponded to the three-stage changes of the "rise-stability-decline" in the stress field, the "gradient-synchronization-differentiation" in the velocity field, and the "delayed initiation-rapid growth-stable saturation" of the interfacial bonding rate. Experimentally, the composite tubes displayed a sound macroscopic morphology with a straight and continuous interface. The errors in macroscopic dimensions such as diameter and length were within 5% compared to simulation results, confirming the reliability of simulation analysis. Additionally, the interfacial shear strength reached approximately 69.97 MPa, with fracture occurring in the aluminum matrix in a ductile manner. A diffusion layer of about 1.5 μm was observed at the interface, indicating metallurgical bonding. In conclusion, the established finite element model successfully simulates the dynamic composite process of Cu/Al clad tubes during three-roll skew rolling and reveals the evolution of field variables at the metal bonding interface, providing theoretical guidance for the study of three-roll skew rolling processes of bimetallic composite tubes.

导出引用

侯文静, 陈鹏, 牛辉, 付伦, 和东平, 王涛. 铜/铝复合管三辊斜轧的结合过程模拟与实验验证[J]. 精密成形工程. 2025, 17(11): 68-78 https://doi.org/10.3969/j.issn.1674-6457.2025.11.006

HOU Wenjing, CHEN Peng, NIU Hui, FU Lun, HE Dongping, WANG Tao. Simulation and Experimental Verification of the Bonding Process in Three-roll Skew Rolling of Cu/Al Composite Tubes[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 68-78 https://doi.org/10.3969/j.issn.1674-6457.2025.11.006

中图分类号： TG339

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