铝合金空心轴形孔同步成形协调机制与智能调控

doi:10.3901/JME.260179

摘要/Abstract

摘要： 针对目前钢制空心车轴生产中存在重量大、制造成本高、能源消耗大等问题，提出以7系铝合金替代钢制空心轴，采用形孔同步成形制造空心轴类件新工艺。基于ABAQUS建立7075铝合金空心轴形孔同步成形数值模拟仿真模型，分析不同压下率、偏转角以及顶头前伸量对斜连轧轧卡现象的影响，以及两组辊转速、偏转角对成形件壁厚和不圆度的影响规律，通过双输入双输出模糊控制器控制轧辊转速和夹具牵引速度，提高轧件几何数据获取精度。研究结果表明，7075铝合金斜连轧中内扩径率是判断轧卡的重要指标，若选择不当的工艺参数会导致斜连轧轧卡现象的产生，导致轧制无法完成。但过低轧辊的转速和偏转角均会导致轧件壁厚均匀性下降，造成局部出现轧件圆度下降现象，并通过设计模糊控制器与有限元求解器耦合，实现轧辊与夹具运动的实时调控，当模糊控制后，轧件数据波动集中在0.07～0.15，最大值与最小值的差距缩小约38%，表明采用模糊控制读取轧件几何数据能有效控制轧件壁厚均匀性和圆度，为实现智能化制造高精度铝合金空心轴提供新思路。

关键词: 形孔同步, 7075铝合金, 空心轴, 模糊控制, 算法优化

Abstract: A new manufacturing process is proposed to address the high weight, cost, and energy consumption associated with conventional steel hollow railway axles. In this approach, 7xxx series aluminum alloy is utilized to replace steel, and a shape-hole synchronous forming method is employed for the production of hollow axle components. A finite-element model of the 7075 aluminum alloy hollow axle forming process is established in ABAQUS. The influences of reduction ratio, roll yaw angle, and mandrel advance amount on rolling-lock phenomena during skew rolling are analyzed, along with the effects of dual-roll rotational speed and yaw angle on wall thickness uniformity and ovality. A dual-input dual-output fuzzy controller is implemented to regulate roll rotational speed and gripper traction velocity, thereby enhancing the accuracy of geometric data acquisition. The internal expansion ratio is identified as a critical indicator for predicting rolling-lock occurrences. Improper parameter selection is demonstrated to initiate rolling-lock and terminate the process prematurely. Conversely, excessively low roll speeds or yaw angles are found to deteriorate wall thickness uniformity and induce localized ovality increases. Through coupling of the fuzzy controller with the finite-element solver, real-time adjustment of roll and gripper motions is achieved. After fuzzy control implementation, data fluctuation is confined within the 0.07-0.15 range, and peak-to-valley deviation is reduced by approximately 38%. The results confirm that fuzzy-controlled acquisition of geometric data effectively improves wall thickness uniformity and circularity, providing a new approach for intelligent manufacturing of high-precision aluminum alloy hollow axles.

Key words: shape-hole synchronization, 7075 aluminum alloy, hollow axle, fuzzy control, algorithm optimization

中图分类号:

TG156

束学道, 陈宇森, 王英, 代月晨, 左锦荣, 张庆东. 铝合金空心轴形孔同步成形协调机制与智能调控[J]. 机械工程学报, 2025, 62(6): 121-131.

SHU Xuedao, CHEN Yusen, WANG Ying, DAI Yuechen, ZUO Jinrong, ZHANG Qingdong. Coordination Mechanism and Intelligent Regulation of Simultaneous Forming of Hollow Shaft-shaped Holes in Aluminum Alloys[J]. Journal of Mechanical Engineering, 2025, 62(6): 121-131.

导出引用管理器 EndNote|Reference Manager|ProCite|BibTeX|RefWorks

链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.260179

http://www.cjmenet.com.cn/CN/Y2025/V62/I6/121

参考文献

[1] DOMBLESKY J P，SHIVPURI R，PAINTER B. Application of the finite-element method to the radial forging of large diameter tubes[J]. Journal of Materials Processing Technology，1995，49(1-2)：57-74.

[2] JANG D Y，LIOU J H. Study of stress development in axi-symmetric products processed by radial forging using a 3-D non-linear finite-element method[J]. Journal of Materials Processing Technology，1998，74(13)：74-82.

[3] 杨程，路星星，孙跃，等. 空心轴成形技术研究现状[J].锻压技术，2018，43(1)：1-8. YANG Cheng，LU Xingxing，SUN Yue，et al. Current research status of hollow shaft forming technology[J]. Forging & Stamping Technology，2018，43(1)：1-8.

[4] SUKHORUKOV R Y，SIDOROV A A，ALIMOV A I，et al. Mathematical and physical modeling of the rolling process of tapered shafts for aviation purposes[J]. Advanced Materials & Technologies，2016(1)：9-17.

[5] SUKHORUKOV R Y，SIDOROV A A，ALIMOV A I，et al. Physical and numerical modeling of the process of rolling off of a tapered shaft of aviation purpose[J]. Journal of Machinery Manufacture and Reliability，2016，45(6)：538-545.

[6] ROMANENKO V P，STEPANOV P P，KRISKOVICH S M. Production of hollow railroad axles by screw piercing and radial forging[J]. Metallurgist，2018，61(9-10)：873-877.

[7] ROMANENKO V P，ROMANTSEV B，AILLARIONOV G P，et al. Billet preparation method for railcar hollow axle production[J]. Metallurgist，2014，58(7-8)：684-688.

[8] TAHERIZADEH A，NAJAFIZADEH A，SHATERI R，et al. Comparison of mechanical and metallurgical properties of hollow and solid forged products[J]. Journal of Materials Processing Technology，2006，178：181-187.

[9] 李立峰，蔺昊，王正军，等. 浅谈铁路货车车轴锻造生产线选择[J]. 中国新技术新产品，2019(6)：57-58.

LI Lifeng，LIN Hao，WANG Zhengjun，et al. A brief discussion on the selection of railway freight car axle forging production line[J]. China New Technologies and Products，2019(6)：57-58.

[10] 梁晓捷，陈民涛，胡运宝，等. 42CrMo合金结构钢空心轴类锻件热处理方法及其制备的空心轴类锻件：中国，CN113604649B[P]. 2023-05-16.

LIANG Xiaojie，CHEN Mingtao，HU Yunbao，et al. Heat treatment method for hollow shaft forgings made of 42CrMo alloy structural steel and the prepared hollow shaft forgings：China，CN113604649B [P]. 2023-05-16.

[11] 杜诗文，孙瑞环，李永堂. 圆弧砧结构尺寸对列车车轴成形质量影响[J]. 塑性工程学报，2015，22(6)：26-31.

DU Shiwen，SUN Ruihuain，LI Yongtang. Influence of the structural dimensions of the circular arc anvil on the forming quality of train axles[J]. Journal of Plasticity Engineering，2015，22(6)：26-31.

[12] 张琦，母东，靳凯强，等. 旋转锻造成形技术研究现状[J]. 锻压技术，2015，40(1)：1-6.

ZHANG Qi，MU Dong，JIN Kaiqiang，et al. Current research status of rotary forging technology[J]. Forging & Stamping Technology，2015，40(1)：1-6.

[13] 王聚存，田天泰，张以升，等. 航空发动机用薄壁细长轴旋锻校形工艺研究[J]. 塑性工程学报，2020，27(11)：91-96.

WANG Jucun，TIAN Tiantai，ZHANG Yisheng，et al. Study on rotary forging correcting process of thin-walled slender shaft for aeroengine[J]. Journal of Plasticity Engineering，2020，27(11)：91-96.

[14] 双远华，王付杰，王清华. 无缝钢管连续斜轧工艺与设备的探索[J]. 机械工程学报，2017，53(10)：18-24. SHUANG Yuanhua，WANG Fujie，WANG Qinghua. Explorative study of tandem skew rolling process and equipment for producing seamless steel tubes[J]. Journal of Mechanical Engineering，2017，53(10)：18-24.

[15] 尹元德，张宇，王纯凯，等. 轧辊参数对斜轧穿孔变形过程及内折叠的影响[J]. 钢铁研究学报，2024，36(4)：490-501.

YIN Yuande，ZHANG Yu，WANG Chunkai，et al. Effect of roll parameters on deformation process and inner folding in rotary tube piercing process[J]. Journal of Iron and Steel Research，2024，36(4)：490-501.

[16] 王清华，孙继芸，胡建华，等. 基于深度神经网络的斜轧穿孔机调整参数预测[J]. 锻压技术，2023，48(11)：73-78，103. WANG Qinghua，SUN Jiyun，HU Jianhua，et al. Prediction on adjusting parameters for skew rolling puncher based on deep neural network[J]. Forging & Stamping Technology，2023，48(11)：73-78，103.

[17] PATER Z，BULZAK T，TOMCZAK J. Numerical analysis of a skew rolling process for producing a stepped hollow shaft made of Titanium alloy Ti6Al4V[J]. Archives of Metallurgy and Materials，2016，61(2)：677-682.

[18] PATER Z，TOMCZAK J，BULZAK T，et al. Conception of a three roll cross rolling process of hollow rail axles[J]. ISIJ International，2021，61(3)：895-901.

[19] PATER Z，BULZAK T，TOMCZAK J. Problems of forming stepped axles and shafts in a 3-roller skew rolling mill[J]. Journal of Materials Research and Technology，2020，9(5)：10434-10446.

[20] ZHANG S，SHU X D，XIA Y X，et al. Formation mechanism and control of the spiral marks of three-roll skew-rolled hollow axles[J]. Metalurgija，2021，60(1-2)：51-54.

[21] 陈潜，束学道，李依蔓，等. 航空发动机涡轮轴穿轧一体化成形工艺及其数值模拟与分析[J]. 宁波大学学报(理工版)，2023，36(6)：24-29.

CHEN Qian，SHU Xuedao，LI Yiman，et al. Piercing-rolling integrated forming process of aero-engine turbine shaft and itsnumerical simulation and analysis[J]. Journal of Ningbo University，2023，36(6)：24-29.

[22] YE Caoqi，SHU Xuedao，WANG Jitai，et al. The influence of process parameters on the axial force of the continuous rolling section in the synchronous forming process of shape and inner hole for hollow axles[J]. Materials Research Proceedings，2024，44：519-527.

[23] 陈晨，双远华，陈建勋，等. 钛合金无缝管斜连轧新工艺研究[J]. 稀有金属材料与工程，2023，52(3)：959-967. CHEN Chen，SHUANG Yuanhua，CHEN Jianxun，et al. New process research on tandem skew rolling of Titanium alloy seamless tube[J]. Rare Metal Materials and Engineering，2023，52(3)：959-967.

[24] 王廷溥. 金属塑性加工学：轧制理论与工艺[M]. 北京：冶金工业出版社，1988. WANG Tingpu. Metal plastic processing：Rolling theory and technology[M]. Beijing：Metallurgical Industry Press，1988.

[25] 郑凡林. 强力错距旋压7075铝合金管材塑性成形机理的研究[D]. 太原：太原理工大学，2022. ZHENG Fanlin. Research on plastic forming mechanism of 7075 Aluminum alloy tubes prepared by power staggered spinning[D]. Taiyuan：Taiyuan University of Technology，2022.

[26] ZHENG J B，SHU X D，LI Z X，et al. The deformation behavior and microstructure evolution of cladding tube during spinning composite process of Mg/Al tube[J]. Journal of Materials Engineering and Performance，2024，34：5721-5734.