豆形截面钢丝辊模拉拔工艺数值模拟研究

采用二辊五道次辊模拉拔方法成形豆形截面钢丝.依据豆形截面钢丝形状的特殊性及AISI70号钢材的特性，设计了各道次孔型形状.其中第一、二、四、五道次的道次压缩率相等，辊子采用横辊摆放；第三道次的道次压缩率为0，该道次的辊子采用与横辊呈90°的立辊摆放.计算并设计出各道次辊模组成的孔型型腔的截面尺寸和形状，再利用Deform-3D模拟软件对五道次辊拉拔过程进行仿真模拟，分析了工件辊模拉拔过程的变形机理，并对辊模拉拔过程中工件的等效应力、等效应变、模具的载荷等进行了分析，同时选取特殊点进行应力应变比较.研究结果表明，通过辊模拉拔方法生产的豆形截面钢丝，其成形效果良好.

Simulation Research on Roll Die Drawing Process for Bean-shaped Steel Wire

According to the particularity of bean-shaped cross-section steel wire and characteristics of AISI70 steel,groove shapes in five processes are designed and roll die drawing process is adopted in this paper.The compression ratio in the first,second,fourth and fifth process is equal,and the roll dies are horizontal.The third process compression rate is 0 and the roll dies are vertical,whose angle is 90° compared with horizontal roll dies.The sizes of groove cavities and roll dies shapes are designed.A 3D finite element model of roll die drawing process of the bean-shaped steel wire is developed under the Deform-3D platform and the plastic deformation process of the billet is analyzed.Based on this accurate 3D FE model,the forming laws of roll die drawing of bean-shaped steel wire are illustrated,which includes effective stress distribution and evolution,effective stain distribution and evolution and the load of roll dies.Meanwhile,several special points are tracked to present the effective stain histories during the roll die drawing process.The result shows that forming effect of bean shaped steel wire is good through the process of roller die drawing.This paper provides technical support for the practice of bean-shaped cross-section steel wire.