单榫头叶片锻造过程应力应变场的三维有限元分析

为了获得单榫头叶片锻造过程中应力，应变场的分布规律，利用自行开发的三维有限元模拟分析软件对其成形过程进行了模拟分析，研究结果表明，单榫头叶片锻造过程是非稳态的塑性流动过程，叶身横截面内的变形类似于圆柱体的镦粗，且心部所受的变形和三向压应力最大；随着变形程度的增加，等效应力，等效应变等变量值增加，且变形的不均匀程度也在增加；通过对应力应变的分析可以预测缺陷产生的可能部位，并提出相应的防止措施，该研究对了解和掌握叶片锻造过程的变形规律具有重要意义。     

盘形锻件等效应力分析及神经网络预测

锻件等效应力对锻件质量有较大的影响,而实现其在锻造生产中的在线测量并进行综合评价较为困难.利用弹塑性有限元法对钛合金盘形锻件进行有限元仿真分析并进行了实验验证,分析了加载完成后等效应力的分布情况;利用灰关联分析方法对结果进行分析,结果表明坯料初始温度对锻件等效应力影响程度最大,室温影响最小.基于等效应力分布情况,利用主成分分析法建立应力综合评价模型,以坯料温度、模具温度、下压速度、室温、摩擦因数为输入层,应力综合评价值为输出层,建立了预测综合等效应力的反向传播(back propagation,BP)人工神经网络模型.结果表明BP神经网络的预测结果与实验所得结果较为一致,证明了建立的人工神经网络模型对综合等效应力预测的有效性.该神经网络模型既可在锻造生产中根据工艺参数实现锻件的应力综合评价值在线预测,又可间接对锻造工艺进行评价,并与其他在线测量方式获得的质量信息相结合,为锻造生产的质量控制与工艺改进提供依据.     

基于热力耦合的连杆锻造毛坯优化模拟

针对连杆锻造中高能耗、材料利用率低且成型中易出现"缺料"和"折叠"等缺陷,利用有限元软件Deform-3D模拟分析连杆锻造成型过程,预测成型中材料流动、填充、应力、应变、载荷和温度场的变化趋势,探讨并优化坯料形状对连杆成型性能的影响规律,为连杆锻造工艺制订和模具设计提供参考。     

基于Deform的外轮成形工艺及结构优化

基于Deform软件对某厂生产的汽车外轮成形工艺进行模拟.针对成形过程中出现坯料充不满、锻件上产生折叠、下模冲头容易开裂等现象,分析了成形过程中的金属流动方向和锻造模具所受应力分布,通过减小应力集中、优化锻模倒角、改进锻造过程中金属流向及工艺参数,有效地避免了冲头开裂、锻件折叠和坯料充不满等问题.实践生产表明,对模具的改进和工艺的优化为产品量产提供了理论基础.     

TC6钛合金高温变形本构方程的建立

通过Gleeble-3500热模拟实验机获得了TC6钛合金在变形温度为800~980℃,应变速率为0.5~5s-1,变形程度为30%和60%时的应力-应变曲线。利用高温变形机理分析了热变形参数对流动应力的影响规律,建立了可用于锻造过程数值模拟的TC6合金高温变形的本构方程。     

TC11钛合金叶片精锻过程三维热力耦合有限元模拟

钛合金叶片是航空工业的重要零件,其锻造过程复杂,容易产生缺陷。针对这种情况,运用三维造型软件Pro/E创建叶片模具,模拟不同参数下的成形过程,得到叶片的温度场、等效应力场和等效应变场。分析表明始锻温度对金属流动性和成形质量起关键作用,较高的变形温度加剧原子的热运动,降低金属的变形激活能,减小金属的变形抗力,提高金属的塑性,叶片应力场与应变场趋于均匀,利于获得性能良好的叶片.     

TC4钛合金叶片终锻成形过程仿真

叶片是航空发动机的重要零部件之一,合理的预锻件及锻造工艺有利于改善叶片的锻件性能。基于三维造型软件Pro/E创建叶片及其模具的几何模型,并利用有限元分析不同参数下的温度场、应力场、应变场的变化情况。研究结果表明:当温度为950℃,摩擦因子为0.1时,下压速度为20~40mm/s,有利于减少应力集中,提高锻件的质量,并延长模具的使用寿命。研究结果为TC4钛合金终锻工艺的制定提供理论依据。     

基于正交试验的转向节热模锻工艺参数优化

以转向节锻造工艺参数为研究对象,设计了正交试验方案,并运用Deform-3D软件对转向节热锻成形过程进行了数值模拟.研究上模下压速度、摩擦因数、坯料初始温度和阻力墙高度对热锻成形过程中的金属流动、锻件填充效果、成形载荷及锻件本体损伤的影响.最终确定的最优成形工艺参数为上模下压速度200 mm/s、摩擦因数0.3、坯料初始温度1 275℃、阻力墙高度2.5 mm.     

螺杆钻具橡胶衬套的生热及热力耦合分析

针对螺杆钻具中最易发生失效的定子橡胶衬套,应用传热学原理,采用有限元法分析了常规型和等壁厚橡胶衬套的热力耦合效应,讨论了橡胶温升的物理机理。分析了衬套的温度场分布特点,比较了温度变化对两种橡胶衬套的应力应变影响,研究了静压、转子转速、橡胶硬度、泊松比、地层温度和压差对衬套温升的影响。研究发现：常规型衬套温度场呈椭圆形分布,而等壁厚衬套温度分布较为均匀;温度越高,衬套的热应力和变形就越大;相同工况下,等壁厚衬套的温升及应力应变均小于常规型衬套;常规型衬套的温升随静压、转子转速和压差的增加而增大,随橡胶硬度、泊松比及地层温度的升高而减小,但这些参数对等壁厚衬套温升量的影响非常小。     

U71Mn钢重轨轨头淬火应力场的计算机模拟

采用有限元法研究了重轨轨头在淬火过程中的应力场分布。在模拟计算过程中利用等效热容法处理相变潜热对温度场的影响,利用等效线膨胀系数法处理相变引起的组织应力,并考虑了材料非线性参数对温度场的影响。结果表明,温度模拟结果与实测结果相吻合,同时喷风淬火能产生较小的残余热应力,从而避免了钢轨的变形和开裂。     

Deformation and Densification Laws of Powder Cold Forging

The deformation and densification laws of preform upsetting and closed-die forging were researched based on experimental results of cold forging of deoxidized Fe powder sintering porous material under different initial conditions such as friction factor, ratio between height and diameter and relative density. The fracture limit criteria＂ for powder cold-forging upsetting and the limit strain curve were achieved. The effect of friction facto,, ratlt, between height and diameter and relative density on fracture strain limitation was emphatically analyzed. The limit process parameter curves for the deformation of upsetting were also confirmed. Laws of deformation, densification and density distribution for closed-die forging of powder perform during cold-forging were further analyzed and discussed with the help of experimental phase analysis. As a result, this experiment established theoretical foundations for the design of preform and die as well as optimization of technological process parameters.     

汽车发电机爪极浮动凹模双向闭式挤压热锻工艺

针对汽车发电机爪极生产时存在成形载荷大、金属流动不均匀、工艺复杂等问题,提出1种浮动凹模双向闭式挤压热锻成形工艺。利用Deform-3D软件对爪极零件成形过程进行数值模拟,分析爪极零件成形过程中的金属流动情况、成形力、合模力等,且进行工艺实验。模拟结果表明:采用浮动凹模双向闭式挤压热锻成形工艺生产汽车发电机爪极,工序简单,且能够改善金属的流动,降低成形力,提高材料利用率。工艺实验证明了采用浮动凹模双向闭式挤压热锻成形工艺生产汽车发电机爪极的可行性。     

A phenomenological constitutive equation for Rene 95 PM alloy and its application to isothermal forging process of turbine disk

The flow behavior of Rene 95 PM alloy was studied from 1050 to 1150℃ with strain rate of 1x10-3, 1x102,1x101and 1 s-2. At a given temperature and strain rate, flow curves exhibit a peak followed by flow softening up to a steady state. Moreover, at constant strain, flow stress increases with increasing strain rate and decreasing temperature. An equation relating hyperbolic sine of flow stress to hot working parameters, such as strain, strain rate and temperature, was established by using multiple nonlinear regression method. A very good agreement was found between predicted and experimental flow stress in all the strain range investigated. Application of the constitutive equation in predicting forming loads and flow behavior and temperature distribution in both upper and lower dies in an isothermal forging process of turbine disk of large dimension (about 630 mm) by means of a finite element code was systematically analyzed.     

航空发动机叶片精锻成形过程的热力耦合数值模拟

采用热力耦合数值模拟方法对高温合金IN718单榫头叶片精锻成形工艺过程进行了模拟研究.研究结果表明:在叶片成形过程中塑性变形功和摩擦功所带来的升温效应和坯料与模具之间的热传递所引起的冷却效应对温度场、等效应力场以及载荷一时间曲线的影响较大;不同摩擦系数对叶片精锻过程的影响也比较明显;成功解决了叶身和榫头交界处出现的缩颈问题;通过模拟结果对比分析,进一步验证了本模拟过程分析的合理性和实用性.     

发动机叶栅的实验研究和数值预测

在暂冲式跨音速平面透平叶栅风洞上对某叶栅进行了吹风试验。通过数值预估实验叶栅流场,提供了流场大体结构,设计了实验方案。为选择压力传感器量程和布置测点位置提供了依据。实验测量得到了设计安装角及变工况下叶片表面压力、叶片表面等熵马赫教及波系结构随叶栅进口气流角的变化,并对叶栅内部及出口流场进行了纹影照相。数值预测与试验结果相比较,在大部分情况下,吻合得很好,说明了计算程序的可靠性。反过来,试验结果又可用于检验和改进N.S方程计算程序。     

45#钢锻件热镦粗过程晶粒尺寸模拟

应用自主开发的镦粗过程锻件组织模拟软件 ,对 45 #钢热镦粗过程中的晶粒尺寸进行了模拟 ,得到了不同压下量下的应变场、应变速率场以及动态再结晶晶粒尺寸的等值线 ,并分析了压下量对各场变量变化规律的影响 .     

Investigation of performances and flow characteristics of two bi-directional pumps with different airfoil blades

Today, the most commonly used bi-directional airfoil in hydraulic machinery is the S-shaped airfoil (SA). A new bi-directional airfoil, obtained by lowering the bent airfoil camber and thickening the bone line bi-directionally, is proposed. Two bi-directional axial flow pumps, with the SA blades and the arc airfoil (AA) blades, respectively, were designed to verify the applicability of this airfoil. By comparing the hydraulic performances of the two pumps obtained from the experiments, and the cavitation performance and flow field of the two pumps obtained from numerical simulations, it was found that AA blades can improve both the hydraulic and cavitation performances under a low flow rate and near the best efficiency flow point (BEP), whether in forward or reverse operation for the bi-directional axial-flow pump. Furthermore, the hydraulic performance of the AA blade pump declines sharply in a large flow rate compared to that of the SA blade pump. The location and composition of the inhomogeneous flows inside the impellers of the two pumps are similar. However, the SA blades work on fluid, mainly at the front half of the blades, which is a distinctive feature from the AA blades and may be a universal phenomenon in all SA-type blades.