旋轮结构对强力旋压成形规律的影响

doi:10.3901/JME.2025.24.096

摘要/Abstract

摘要： 深入探讨在筒形件强力旋压成形过程中采用环形旋轮和传统旋轮时在旋压成形特征上产生的差异及其对坯料变形的影响。设置干涉试验对比分析两种旋轮在成形过程中产生的变形区在几何上的差异；通过有限元分析方法，模拟两种旋轮的推挤强力旋压成形过程，给出旋压力的计算方法，分析变形区的状态、旋轮载荷和芯轴负载的变化规律和两种旋轮在推挤强力旋压成形后坯料的几何特征。研究发现，相同成形条件下推挤强力旋压配合环形旋轮的应用产生更大的载荷，成形过程表现出更显著的压应力状态和较小的等效塑性应变梯度。具体试验结果如下：在压下量相同时，环形旋轮的使用使干涉包角扩大约1.5倍；环形旋轮和芯轴在推挤旋压过程中承受更大的载荷，约为传统旋轮成形过程的1.5倍；环形旋轮在推挤强力旋压中产生的应力三轴度更低且更均匀：R16、R17、R18位置的应力三轴度最大差值分别为：0.55、0.39、0.74；环形旋轮成形后产生的回弹量(0.15 mm)约为传统旋轮(0.35 mm)的43%，且壁厚均匀度更好；环形旋压成形获得的坯料沿圆周方向壁厚误差小于0.001 mm；环形旋轮促进了坯料的扭转变形并优化了扭转的均匀性。

关键词: 推挤强力旋压, 旋轮结构, 应力三轴度, 有限元分析, 载荷

Abstract: Delving into the application of power spinning technology in the shaping of cylindrical components, examining the disparities in forming characteristics between ring rollers and conventional rollers, as well as their respective influences on the deformation behavior of the workpiece. An interference test was conducted to assess the geometrical differences in the deformation zones generated by the two types of roller during the forming process. Finite element analysis was employed to simulate the push power spinning processes for both types of rollers, providing a methodology for calculating the spinning force and analyzing the patterns of deformation zone states, loads on the rollers and mandrel. Additionally, the geometric features of the workpiece after push power spinning with both types of rollers were examined. The findings indicate that under the same forming conditions, the application of push power spinning with ring rollers produced greater loads, and the forming process exhibited a more significant compressive stress state and a smaller gradient of equivalent plastic strain. The specific experimental outcomes are detailed as follows: under equivalent reduction conditions, the ring roller increased the interference wrap angle by approximately 1.5 times; the roller and mandrel experienced higher loads during the push power spinning, approximately 1.5 times greater than those observed in the traditional rollers; the stress triaxiality induced by the ring roller in push power spinning was found to be lower and more uniform, with the maximum differences in stress triaxiality at positions R16, R17, and R18 being 0.55, 0.39, and 0.74, respectively; the springback after forming with the ring roller was approximately 0.15 mm, which is about 43% of that observed with traditional roller (0.35 mm), and the uniformity of wall thickness was superior; the circumferential wall thickness error of the workpiece obtained through ring roller spinning was less than 0.001 mm; the ring roller facilitated the torsional deformation of the workpiece and improved the uniformity of the torsion.

Key words: push power spinning, roller structure, stress triaxiality, finite element analysis, load

中图分类号:

TG306

梁郅睿, 刘东, 王建国, 张宇, 赵佳航. 旋轮结构对强力旋压成形规律的影响[J]. 机械工程学报, 2025, 61(24): 96-108.

LIANG Zhirui, LIU Dong, WANG Jianguo, ZHANG Yu, ZHAO Jiahang. Influence of Roller Structure on the Forming Law in Power Spinning Process[J]. Journal of Mechanical Engineering, 2025, 61(24): 96-108.

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