目的 探究GH4169螺栓温滚丝成形过程中热力耦合机理及多物理场演化规律,为后续开展工艺参数优化及螺纹质量提升工作提供明确的理论指导和模型支撑。方法 利用DEFORM软件建立包含传热与温滚丝加工两阶段的GH4169螺栓温滚丝热力耦合有限元模型,基于此模型对螺纹成形过程的温度场、应力场、速度场及成形力进行数值模拟与理论分析,通过红外测温与滚丝实验对仿真模型的温度及成形力进行验证。结果 实验与仿真模型在冷却阶段的温度误差控制为0.9%,成形阶段的温度误差为7.7%,成形力误差为11.3%,所建模型能够模拟螺纹温滚丝成形过程。工件内部形成由塑性变形生热与喷雾冷却共同作用的“三区域”温度场：中心区域温度均匀（极差<5 ℃）,表层滚压区温差约100 ℃,上下端面温度降至230 ℃;牙底为三向高压应力区（峰值约1 560 MPa）,牙侧以高剪切应力为主,牙顶交替承受径向压缩与轴向拉伸,为潜在拉伸失稳区;滚压接触区的速度场呈现出“低速紊乱-局部高速-沿轮廓均匀分布”的趋势,牙侧材料塑性流动速度的不对称性是牙顶产生折叠的重要诱因;成形力随变形速率变化显著,在进给阶段后期内因加工硬化,成形力达峰值约83.5 kN,于静滚压时随应力释放而下降。结论 所建立的有限元模型能够准确反映GH4169螺栓温滚丝成形过程的热物性规律,揭示牙顶折叠的形成机制,为温滚丝工艺研究提供指导。
Abstract
The work aims to investigate the thermo-mechanical coupling mechanism and the evolution of multi-physical fields during the warm thread rolling of GH4169 bolts, so as to provide theoretical guidance and modeling support for subsequent process optimization and thread quality improvement. A thermo-mechanically coupled finite element model incorporating both the heat transfer stage and the warm thread rolling stage was established in DEFORM, and the temperature, stress, and velocity fields as well as the forming force during thread formation were numerically simulated and theoretically analyzed. Infrared thermometry and rolling experiments were conducted to validate the simulated temperature and forming force. The deviations between experiment and simulation were controlled within 0.9% for temperature during cooling, 7.7% for temperature during forming, and 11.3% for forming force, indicating that the developed model could effectively reproduce the warm thread rolling process. A “three-zone” temperature field was formed inside the workpiece due to the combined effects of deformation-induced heating and spray cooling: the core region exhibited a uniform temperature (range <5 ℃), the surface rolling zone showed a temperature difference of about 100 ℃, and the end faces was cooled to approximately 230 ℃. The thread root experienced a triaxial compressive stress state (peak of about 1 560 MPa), the flanks were dominated by high shear stress, and the crest alternated between radial compression and axial tension, representing a potential tensile instability zone. The velocity field within the rolling contact region displayed a pattern of “low-speed turbulence-localized high speed-contour-aligned uniformity”, and asymmetry in the plastic flow velocity on the two flanks was identified as a major contributor to crest folding. The forming force varied markedly with the deformation rate, reaching a peak of about 83.5 kN in the later feeding stage due to work hardening and decreasing during stable rolling as stress was released. The developed finite element model accurately captures the thermo-mechanical behavior of GH4169 warm thread rolling, reveals the formation mechanism of crest folding, and provides guidance for the design and optimization of warm thread rolling processes.
关键词
GH4169 /
热力耦合 /
塑性变形 /
牙顶折叠 /
有限元模型
Key words
GH4169 /
thermo-mechanical coupling /
plastic deformation /
crest folding /
finite element model
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基金
河南省紧固连接技术重点实验室项目（XM2024-HK17）; 苏州市科技成果转化项目（SZC202317）
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