【作者】 武大鹏；

【导师】 陈文琳；

【作者基本信息】 合肥工业大学 ， 材料加工工程， 2010， 硕士

【摘要】 异形钢丝在纺织、汽车、机械等方面有广泛的应用。矩形钢丝是异形钢丝的一种,传统的成形方法是采用固定模拉拔成形矩形钢丝,但成形时存在如周边圆角充不满,模具周边磨损不均匀导致模具寿命低等问题,很难实现大批量生产。本文以具体钢丝产品为研究对象,主要研究内容如下:首先,研究了现有矩形钢丝成形方法的特点,成形过程的变形特征,分析了工艺参数对成形的影响,在此基础上提出了辊拉组合法成形的工艺方案。其次,以材料为Q195,尺寸为2.3㎜×4.8㎜的矩形钢丝为研究对象,根据有限元理论,建立矩形钢丝拉拔成形三维有限元模型,并利用H.G公式验证了模型的正确性。再其次,利用模型对辊拉组合成形进行了模拟,分析了成形过程中金属的流动特点和应力应变分布规律,验证了辊拉组合法成形工艺方案的可行性。最后,采用正交试验设计方法分析了工艺参数对辊拉组合成形过程中影响,并对试验结果进行极差分析,得到最优化的工艺参数组合。结果表明,对于材料为Q195,尺寸为2.3㎜×4.8㎜的矩形钢丝通过辊拉组合成形,可使钢丝的圆角半径最小达到0.17㎜,满足产品的使用要求,并且模具的磨损量小,具有较高的模具寿命。辊拉组合法成形对其它异型钢丝成形具有一定的借鉴作用。更多还原

【Abstract】 Special-shaped wire is widely applied in the textile, automobile and machinery. Rectangular wire is a kind of it, which is shaped by die drawing traditionally. However, there are many problems when drawing it, such as fillet incomplete filling and nonhomogeneous wear of the die that reduces the life of die, thus it is hard to realize the mass production. In this paper, specified wire is regarded as the research object, and main studies are as follows:Firstly, forming characteristics of the existing methods and the deformation features of forming process are studied, and the effect of process parameters on shaping is analyzed. The combination method is brought forward to drawing rectangular wire on the basis.Secondly, taking rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜ as the research object, and three-dimensional finite element modeling of drawing is established according to the finite element theory. The correctness of the model is confirmed by H.G formula.Thirdly, the forming process with combination method is simulated by the finite element model and metal flow characteristics and the law of stress and strain distribution are studied. It is verified that it is available to shape rectangular wire with combination method.Last, orthogonal experiment design method is used to analyze the effect of process parameters to forming course, and the optimized combination of process parameters are obtained by employing range analysis to analyze the simulation results.The results show that, rectangular wire with raw material for Q195 and the size for 2.3㎜×4.8㎜, it is able to acquire the minimum radius of fillet 0.17㎜ with combination method. Meanwhile, it can also meet the requests for utilization and the life of die is longer due to little wear. Combination method has some for helpful references to shaping other special-shaped wire.更多还原