基于响应曲面法的大型锥形件缩口成形工艺设计及多几何参数优化  

Process Design and Multi-geometric Parameter Optimization of Large Cones Based on Response Surface Methodology

作　　者：吴昂 吴莹 李国俊[1] 李旭斌[1] 张治民[1] WU Ang;WU Ying;LI Guojun;LI Xubin;ZHANG Zhimin(School of Material Science and Engineering,North University of China,Taiyuan 030051;Quality Testing Center,Jinxi Industry Group Co.,Ltd.,Taiyuan 030027)

机构地区：[1]中北大学材料科学与工程学院,太原030051 [2]晋西工业集团有限责任公司质检中心,太原030027

出　　处：《机械工程学报》2019年第24期83-92,共10页Journal of Mechanical Engineering

摘　　要：提出一种适用于大型锥形件的缩口成形方法,通过主应力法对该缩口成形时的轴向缩口力与标准直壁锥形件的缩口力进行对比,得出了最佳成形方案。并基于Deform和响应曲面法讨论了该成形模具中缩口凹模母线弦高χ、内壁直空比l/h和毛坯壁厚S0、变壁厚尺寸λ分别对缩口件高度和缩口成形力的影响,得到了两个响应变量分别关于四个自变量的回归预测模型,优化出凹模内直空结构和毛坯的最佳几何结构参数,最后通过物理试验得到验证。结果表明:当χ=6.9 mm、l/h=0.3、S0=29.5 mm、λ=4.8 mm时,毛坯在缩口过程中未发生失稳,实时最大缩口力为1 920 kN,测量缩口件高度为1 108 mm,与模型预测结果误差均小于10%,说明了该工艺方案中缩口凹模和毛坯结构参数的可行性,其成形工艺及模具结构形式将为大型锥形产品的缩口成形提供理论指导。A necking forming method suitable for large conical parts is presented in this paper, the axial necking force of the necking forming is compared with the necking force of the standard straight wall cone by the principal stress method and the best forming scheme is obtained. And based on Deform and Response Surface Method, the effects of the generatrix chord height χ of the necking die, the ratio of straight part and space part l/h and workpiece wall thickness S0, the size of variable wall thickness λ on the height of the formed part and the necking forming force are respectively discussed. Then, regression prediction model with two response variables for each of the four independent variables is obtained and the best geometric parameters of the straight & space structure and the workpiece is optimized. Finally, it is verified by physical experiments. The results show that when χ=6.9 mm, l/h=0.3、S0=29.5 mm, λ=4.8 mm, the workpiece does not destabilize during the necking process, the maximum necking force is 1 920 kN, and the measured formed part height is 1 108 mm, the error with the model prediction result is less than 10%, which indicates the feasibility of the necking die and workpiece structural parameters in the process scheme. The forming process and the die structure will provide theoretical guidance for the necking forming of large cone products.

关 键 词：锥形件 缩口成形 缩口力 缩口件高度 响应曲面 

分 类 号：TG312[金属学及工艺—金属压力加工]