目的 针对薄壳环矢缩径成形过程中材料流动机制尚不明确的问题,进一步明确缩径量对材料流动规律的影响,以指导工艺参数的优化,提升薄壳件成形质量与稳定性。方法 选取外径6.8 mm、壁厚0.2 mm的Q255薄壳作为研究对象,基于弹塑性理论建立薄壳微元模型,利用Ansys Workbench有限元软件进行仿真模拟。通过改变缩径量,结合节点追踪法,系统研究了材料流动规律及应力应变分布特征,并通过成形实验验证数值仿真结果的准确性。结果 材料在缩径过程中呈现显著的双向流动特征,即径向向模具中心汇聚,同时沿轴向向两端扩散;随着缩径量增加,材料流动范围和局部刚度提高,抗皱能力增强,但当缩径量超过一定临界值时,位移梯度及其波动指数会急剧升高,破坏流动均匀性并引发局部应力集中、壁厚减薄与皱褶等缺陷。当缩径量为0.8 mm时,材料流动最为均匀,位移梯度与波动指数处于较低水平,成形稳定性显著提升。结论 研究揭示了缩径量对薄壳材料流动调控的影响机制,当缩径量为0.8 mm时,可有效改善材料流动均匀性并提高成形稳定性,为环矢缩径工艺参数优化提供了理论与实验依据。
Abstract
The work aims to make clear the unclear material flow mechanism in thin shell ring-shaped reduction forming, so as to further clarify the influence of reduction-of-diameter on the material flow patterns to guide the optimization of process parameters and improve the forming quality and stability of thin shells. Taking Q255 thin shell with an outer diameter of 6.8 mm and a wall thickness of 0.2 mm as the research object, and based on the elastoplastic theory, a microelement mechanical model was constructed. Through finite element simulation using Ansys Workbench, combined with node tracking technology, the material flow patterns and stress-strain distribution characteristics were systematically revealed by changing the reduction-of-diameter. The accuracy of the simulation results was verified through forming experiments. The study indicated that material flow exhibited significant bidirectional characteristics during reduction, converging radially toward the mold center while simultaneously diffusing axially toward both ends. Increasing the reduction-of-diameter enhanced the range of material flow and local stiffness, thereby improving wrinkle resistance. However, excessive reduction-of-diameter led to a sharp rise in displacement gradients, disrupting the uniformity of material flow and causing defects such as concentration of local stress and wall thinning. When the reduction-of-diameter was 0.8 mm, the uniformity of material flow was optimal, with displacement gradients and fluctuation indices at relatively low levels, significantly improving forming stability. This study reveals the influencing mechanism of reduction-of-diameter on material flow. When the reduction-of-diameter is 0.8 mm, it can effectively improve the uniformity of material flow and enhance the forming stability. It provides a theoretical and experimental basis for the parameter optimization of the ring-shaped reduction process.
关键词
薄壳 /
环矢缩径 /
材料流动 /
有限元分析
Key words
thin shell /
ring-shaped reduction /
material flow /
finite element analysis
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基金
国家自然科学基金青年科学基金（52108221）; 湖北省科技创新人才计划（2023DJC075）
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