基于ANSYS的铝合金轮毂旋压成形的模拟仿真与参数优化

发布时间：2018-06-29 21:15

本文选题：铝合金轮毂 + 弹塑性　；参考：《长春工业大学》2017年硕士论文

【摘要】：随着人类跨入21世纪,汽车作为人们不可或缺的交通工具,人们追求它高性能的同时也越来越注重它的环保、美观、新能源利用等方面的发展。而汽车轮毂作为汽车的主要部件,在汽车的重量、外观、转向和驾驶方面发挥不可或缺的作用。而小型汽车铝合金轮毂的制造以其美丽的外观、强度高、耐热性好,重量相对较轻,惯性阻力小等优点越来越受人们的欢迎。旋压成形工艺的产生和飞速发展,为很多要求质量高的产品生产提供了新的道路。虽然汽车轮毂的加工成形也有越来越多的企业采用旋压工艺,但是利用金属的塑性成形对铝合金轮毂拉伸旋压并不是一个简单的成形过程。首先,我们这次研究依据以往旋压成形特点,以及结合轮毂旋压成形的实际生产状况,先对模拟成成形较为容易的筒形件用ABAQUS进行强力正反旋的仿真分析,通过对正反旋成形后的等效应力的分析得出一般情况下正旋形式较好。由于软件ABAQUS无法研究毛坯壁厚的变化情况然后等原因我们选择对后期轮毂工件使用ANSYS/LS-DYNA进行模拟仿真分析;然后,介绍了有限元理论(材料的弹塑性、屈服及求解问题),为之后的模拟提供了理论基础,中期主要研究铝合金轮毂的旋压过程进行数值模拟,在模拟的前期阶段我们分析探究了成形过程中旋压的载荷施加、边界条件的确定、运动轨迹及网格划分等主要问题;最后,依照ANSYS/LS-DYNA模拟的数值结果,使用它后处理软件LS-PREPOST观察它的动态仿真成形过程。研究了旋轮进给率、减薄率和摩擦系数等重要参数下的铝合金6A02轮毂在加工过程中应力应变具体数值的规律及其应力云图,分析了应变区金属流动规律,为有效的制定成形工艺方案、及其参数的合理优化提供了有力的依据。通过对进给率、芯模转速、摩擦系数和旋轮圆角半径等几个重要的工艺参数的模拟结果进行分析和以应力应变和成形能量走势为主要判断依据,采用虚拟正交试验设计方法分析优化进给比、摩擦系数等条件对旋压成形质量的影响关系,最终分析得到最优的工艺参数组合。
[Abstract]:As human beings step into the 21st century, the automobile as an indispensable vehicle for people, people pursue its high performance, but also pay more and more attention to its environmental protection, beauty, new energy utilization and other aspects of the development. As the main parts of the automobile, the wheel hub plays an indispensable role in the weight, appearance, steering and driving of the vehicle. For its beautiful appearance, high strength, good heat resistance, relatively light weight and low inertia resistance, the manufacture of aluminum alloy wheels for small cars is becoming more and more popular. The production and rapid development of spinning technology provide a new way for the production of many high quality products. Although more and more enterprises adopt spinning process in automobile hub forming, it is not a simple forming process to use metal plastic forming to draw aluminum alloy wheel hub. First of all, according to the characteristics of spinning forming in the past and the actual production situation of hub spinning, we first simulate and analyze the strong positive and negative rotation of cylindrical parts which are easy to be formed by Abaqus. Through the analysis of the equivalent stress after positive and negative spin forming, it is concluded that the normal rotation form is better in general. Because Abaqus can't study the change of blank wall thickness and so on, we choose ANSYS- LS-DYNA to simulate and analyze the later hub workpiece, and then introduce the finite element theory. In the middle stage, the spinning process of aluminum alloy hub is studied numerically. In the early stage of simulation, we analyze and explore the application of spinning load in the forming process. Finally, according to the numerical results of ANSYS- / LS-DYNA simulation, the dynamic simulation forming process is observed by the post-processing software LS-PREPOST. The specific values of stress and strain and the stress cloud diagram of aluminum alloy 6A02 hub in the process of machining are studied under the important parameters such as feed rate, thinning rate and friction coefficient of the rotating wheel, and the metal flow law in the strain region is analyzed. It provides a powerful basis for the effective formulation of forming process and the reasonable optimization of its parameters. The simulation results of several important technological parameters, such as feed rate, core die speed, friction coefficient and rotary wheel radius, are analyzed, and the main judgment basis is stress strain and forming energy trend. The virtual orthogonal design method is used to analyze the influence of the optimal feed ratio and friction coefficient on the quality of spinning forming. Finally, the optimal combination of process parameters is obtained.
【学位授予单位】：长春工业大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG306

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