基于响应面法的异形截面环件轧制宏观成形缺陷的分析与优化  

Analysis and optimization on acroscopic forming defect for profiled section ring rolling based on response surface method

作　　者：马君慧 吴运新[1,2,3] 龚海 张涛[2,3] 郝铁文 刘磊[2,3] Ma Junhui;Wu Yunxin;Gong Hai;Zhang Tao;Hao Tiewen;Liu Lei(College of Electromechanical Engineering,Central South University,Changsha 410083,China;State Key Laboratory of High Performance Complex Manufacturing,Central South University,Changsha 410083,China;Institute of Light Alloy,Central South University,Changsha 410083,China;CFHI Dalian Engineering&Technology Corporation Limited,Dalian 116600,China)

机构地区：[1]中南大学机电工程学院,湖南长沙410083 [2]中南大学高性能复杂制造国家重点实验室,湖南长沙410083 [3]中南大学轻合金研究院,湖南长沙410083 [4]一重集团大连工程技术有限公司,辽宁大连116600

出　　处：《锻压技术》2022年第9期135-144,共10页Forging & Stamping Technology

基　　金：民用航天预研项目(B0109);高性能复杂制造国家重点实验室自主研究课题(ZZYJKT2021-05);黑龙江省重点研发计划项目(GA21D003)。

摘　　要：缺肉是异形截面环件在轧制过程中容易产生的成形缺陷问题,缺肉程度与异形截面环件几何参数的关联关系十分复杂。建立2219铝合金不对称异形截面环件轧制的数值模型,分析了异形截面环件槽型深度和槽型角度对环件成形质量的影响,通过分析缺肉缺陷的形成机理,提出采用优化毛坯尺寸参数的方式来抑制缺陷。基于响应面法,以槽型深度、槽型角度和毛坯角度为设计变量,以缺肉系数为设计目标,建立了表征缺肉系数的响应面模型,并对该模型进行了回归检验。结果表明,槽型深度越大、槽型角度越小,越容易产生成形缺陷。利用建立的响应面模型对目标槽型深度为45 mm、槽型角度为70°的环件的毛坯角度进行了优化,结果显示优化后的毛坯较好地抑制了缺肉缺陷。Insufficient filling is a problem of forming defects that are easily generated during the rolling process for profiled section rings, and the relationship between the degree of insufficient filling and the geometric parameters of profiled section rings is very complicated. Therefore, the numerical model of asymmetric profiled section ring rolling for 2219 aluminum alloy was established, and the influences of groove depth and groove angle of profiled section ring on the forming quality of ring were analyzed. Then, by analyzing the forming mechanism of insufficient filling defects, the method of optimizing blank size parameters was proposed to suppress the defects. Furthermore, based on the response surface method, taking groove depth, groove angle and blank angle as the design variables and the insufficient filling coefficient as the design goal, the response surface model to characterize the insufficient filling coefficient was established, and the regression test was carried out. The results show that the larger the groove depth is and the smaller the groove angle is, the easier it is to produce forming defects. Using the established response surface model, the blank angle of ring with the target groove depth of 45 mm and the groove angle of 70° is optimized. The result shows that the optimized blank can better suppress the insufficient filling defects.

关 键 词：成形缺陷 不对称异形截面 环件轧制 响应面模型 毛坯角度优化 

分 类 号：TG335[金属学及工艺—金属压力加工]