Two step forging process of spur gear based on rigid parallel motion

To improve the forging process of spur gear,the metal flow rule is investigated in detail,and a hypothesis of radial rigid-parallel-motive (RPM) flow mode is given. Based on the RPM mode a novel specific gear forging technology is put forward by introduced upend forging process and constrained divided-flow technique. Firstly,finite element method is used to simulate the upend forging pre-forming and RPM finish forging,and equivalent stress field and load-stroke curve are investigated. Secondly,a correspondi...     

Investigation on Zener-Hollomon Parameter in the Warm-Hot Deformation Behavior of CF53

The warm-hot deformation behavior of CF53 steel was studied with hot compression tests at temperature of 1 123 ~1 273 K and strain rate of 0.1~20 s -1 . The activation energy for warm-hot deformation is 274.816 kJ/mol. The influences of Zener-Hollomon parameter, strain and grain size imposing on the flow stress were analyzed in the temperature range of warm-hot forging. Based on the creep theory and mathematic theory of statistics, mathematical models of flow stress were obtained. The results provide a scientific basis for controlling microstructure of forging process through Zener-Hollomon parameter.     

Microstructure Evolution of Different Forging Processes for 12％Cr Steel During Hot Deformation

Five forging experiments were designed and conducted to investigate the effect of process parameters on microstructure evolution during hot deformation for X12CrMoWVNbN10-1-1 steel.The experimental results indicated that average grain size became finer with the increasing number of upsetting and stretching.Especially,the size of stretching three times with upsetting twice had the most remarkable effect on refinement,and the size was only 27.36%of the original one.Moreover,the stress model was integrated into the software and finite element models were established.Simulation results demonstrated that the strain at center point of workpiece was far larger than critical strain value in each process,so that dynamic recrystallization(DRX) occurred in each workpiece,which implied DRX could occur for several times with the increasing number of upsetting and stretching,and uniform finer microstructure would be obtained.However,the results also showed that higher temperature was an unfavorable factor for grain refinement,so the times of heating should be limited for workpiece,and as many forging processes as possible should be finished in once heating.     

Multi-scale simulation for the forming of a heavy vessel head considering the evolution of defects and microstructure

The head of nuclear pressure vessel is a key component to guarantee the safety of nuclear power plant, so it is necessary to improve its mechanical properties during manufacturing. In the practical production, due to the huge size of the ingots from which the head is manufactured, coarse grains and voids are common defects existing in the material. Furthermore, cracks may appear in the forming process. It is highly demanded that the forming process must be properly designed with suitable parameters to compact the voids, to refine and homogenize the grains and to avoid cracks. Therefore, the research on the evolution of internal voids, grain size and cracks is very important to determine the forming process of huge components. SA508-3 steel is the material to manufacture the head of pressure vessel in the nuclear island. In the previous studies, we have separately built models to evaluate the evolution of internal voids, grain size and cracks during the hot forming process for SA508-3 steel. This study integrates the models for multi-scale simulation of the forging process of the head of nuclear pressure vessel in order to control the quality of the forgings. Through the software development, the models are integrated with a commercial finite element code DEFORM. Then, the extended forging and final forging processes of the head are investigated, and some appropriate deformation parameters are recommended.     

Research on voids deformation welding condition for manufacturing of heavy forgings

Crushing and diffusion welding are two critical healing stages of interior void defects in heavy forgings. The healing result depends on many factors during the forging process, such as stress, temperature, deformation and type of material, while the void diffusion welding condition is still not well known at the present. This paper is concerned with the deformation welding condition of the closed void interface in heavy ingot during the hot forging process. A void crushing experiment is carried out to recognize the microstructure of the closed void interface. According to the healing mechanism at high temperature, a new physical simulation model is setup to study the deformation welding process of the closed void interface based on the theory of atom diffusion and the interface contact mechanics prototype. Compared with the experimental results, the influence of deformation degree, forming temperature and holding time on the welding quality is discussed, and then the deformation welding condition of closed void interface is presented. The proposed condition helps to improve forging technology and product quality.     

纳米化对1Cr17不锈钢耐高温氧化的影响

喷丸处理可以使铁素体不锈钢1Cr17实现表面自身纳米化.对不同工艺的试样进行在高温空气介质中的耐氧化试验,结果表明1Cr17不锈钢经纳米化喷丸后,在氧化20 h后材料的表面可以形成一层富Cr的致密的内氧化物层,有效的防止了材料的进一步氧化.喷丸后又经过退火的试样,在氧化12 h时表面就形成了一层致密的内氧化物层,因为退火可以有效地释放因为喷丸而产生的压应力,可以更好地促进Cr向表面的扩散,更快的在合金表面形成富Cr的氧化物,从而显著提高了合金的抗高温氧化性.     

超高性能混凝土中钢纤维锈蚀的细观力学分析

为了研究钢纤维体积含量和锈蚀程度对结构强度和变形的影响,通过自行编写Python脚本文件,对ABAQUS软件进行二次开发,实现了钢纤维在超高性能混凝土（UHPC）基体中的大批量随机乱向均匀分布;在此基础上研究了UHPC带缺陷锈蚀模拟方法,进而探索了钢纤维锈蚀的等效方法;最后以UHPC梁四点抗弯试验为例,对UHPC细观力学分析方法、锈蚀的模拟方法和等效手段进行了验证. 研究结果表明:当纤维体积含量为2% 时,UHPC梁的抗弯曲性能最佳;影响锈蚀效应的关键因素为锈蚀造成纤维截面削弱、锈坑附近产生应力集中、界面粘结遭到破坏;采用随机材料属性分配的方式,仅局限于模拟UHPC梁的宏观变形,无法准确模拟应力场分布情况.      

纳米化对1Cr17不锈钢耐高温氧化的影响

喷丸处理可以使铁素体不锈钢1Cr17实现表面自身纳米化.对不同工艺的试样进行在高温空气介质中的耐氧化试验,结果表明1Cr17不锈钢经纳米化喷丸后,在氧化20 h后材料的表面可以形成一层富Cr的致密的内氧化物层,有效的防止了材料的进一步氧化.喷丸后又经过退火的试样,在氧化12 h时表面就形成了一层致密的内氧化物层,因为退火可以有效地释放因为喷丸而产生的压应力,可以更好地促进Cr向表面的扩散,更快的在合金表面形成富Cr的氧化物,从而显著提高了合金的抗高温氧化性.     

Numerical Simulation of Coupled Thermo-mechanical Behavior of a Cylinder Billet during Hot-forging Process

IntroductionInhotforging,variationanddistributiol1oftemperatureplayveryimportantroIeinviewofthermalstressesorthermalstrainaswe1lasthemateria1properties.MechanicaldefOrmationcangenerateheatbyfrictionalslidingand/ordissipatiOI1ofplasticwork.Theboundaryconditionfortemperatureismodifiedbythechangeinmaterialshape.Dietemperatureusuallyislowerthanworkpiecetemperatureandthisfactresultsindiechilling.Itsignificantlyaffectsthetemperatureoftheworkpiecea11d,consequently,alterstheflowstress.Whenthedieisr…     

Numerical simulation of multi-pass rolling force and temperature field of plate steel during hot rolling

Rolling force and temperature field are important parameters in the hot rolling process of plate steel. Most researchers use ANSYS/LS-DYNA and MSC.Marc to simulate the hot rolling process, however, software DEFORM-3D is not used widely in this field. Therefore, in this study, the commercially available finite element analysis software DEFORM-3D is used to simulate the distribution of rolling force, stress-effective, strain-effective and temperature field during the hot rolling process of plate steel with the size of 0.220m×2.070m×1.904m. Both the simulated rolling force and temperature of the multi-pass are compared with the measured results. It is shown that the simulated values by the finite element method are approximate to the measured values in the hot rolling of plate steel. So the simulation can provide an important reference and optimization to make rolling process and parameters in steel factory.     

Forging penetration efficiency of steel H13 stepped shaft radial forging with GFM forging machine

The numerical thermal mechanical simulation of radial forging process of steel H13 stepped shaft with GFM (Gesellschaft fur Fertigungstechnik und Maschinenbau) forging machine was carried out by three-dimensional finite element code DEFORM 3D. According to the effective plastic strain, the mean stress and the mean plastic strain distribution of the radial forging, the forging penetration efficiency (FPE) was studied throughout each operation. The results show that the effective plastic strain in the center of the forging is always greater than zero for the desirable larger axial drawing velocity. The mean stress in the center of the workpiece is proposed to describe hydrostatic pressure in this paper. There is compressive strain layer beneath the surface of the workpiece to be found, while there is tensile strain core in the center of the workpiece. These results could be a valuable reference for designing the similar forging operations.     

Computer Aided Simulation on Precision Cold Forging of Universal Joint Cross

IntroductionThefiwtee1emenmethod(FEM)playsanextrmelyimPortantroleintheanalysesofengineeringproblems.ForalongtimethismethodhasmainlybeenaPPliedinthelinearfieldandshownitsgreatpower.HoweveealOtofnonlinearengineeringPrOblemsWhichcanneitherbesimPlyreducedtolinearonesnorrCPresentedbylinearlyanalogywhichshallchnsethePfacticalconditionsrelativelymuch,havechallengedfiniteelementmethod(FEM).RecentymuchProgresshasbeenmadebothinthemathematicalandmechanicaltheoryandthecomPulertechnologysothatevent…     

某大桥双壁钢围堰结构的三维有限元分析

某特大桥桩基础承台尺寸为10.4m×7.6m,水深11.78m,采用钢围堰排水浇筑施工。为了较准确了解初定钢围堰结构的内力和变形情况,确保工程施工安全,对该钢围堰用ANSYS软件进行了三维有限元静力分析和模拟。分析结果指出,该围堰结构局部杆件需要加强,而有些杆件还可进一步优化,以节约成本。从而说明对于这类复杂工程,进行施工全过程三维有限元分析和模拟是完全必要的。     

波形钢腹板组合梁弯曲变形的三角级数解

为研究波形钢腹板剪切变形对波形钢腹板组合梁弯曲变形行为的影响,采用三角级数拟合简支波形钢腹板组合梁的变形曲线,各构件弯曲变形满足平截面假定,基于最小势能原理,推导了简支和悬臂波形钢腹板组合梁分别在均布荷载和集中荷载作用下的弯曲变形解析解和简化解;基于简化解推导出考虑剪切变形的波形钢腹板组合梁挠度增大系数,并给出对考虑剪切变形影响与否的高跨比界限;采用有限元方法验证了解析解和简化解的正确性和适用性. 研究结果表明:所提方法边界条件明确、推导过程简单、结果可靠、适用性强,可为波形钢腹板组合梁的设计和变形计算提供可靠的依据.      

一种难加工材料的斜角切削过程的数值模拟

参数化建模在仿真切削过程中是行之有效的方法。通过接口设计,系统实现了在Marc中对斜角切削方式的参数化建模。基于金属切削理论和有限元分析原理。借助于有限元方法及材料弹塑性变形理论。针对斜角切削方式,通过建立几何模型、材料模型、刀屑摩擦模型、热控模型和切屑分离准则,采用有限元分析软件Marc,对一种难加工材料的切削过程进行数值模拟,得到在不同切削条件下的切削区应力场、温度场。通过对数值模拟后切削力的结果与实验得到的数据进行比较,验证了所建模型的合理性。     

钢桥面铺装混合料三轴重复加载试验变形特性

为了研究钢桥面铺装材料的高温变形特性及其车辙预估方法,针对MA及SMA两种钢桥面铺装混合料,采用三轴重复加载试验评价其高温性能,并根据试验结果,通过多元线性回归得到材料的非线性计算模型参数,使用ABAQUS有限元软件,模拟三轴试验过程,将计算变形与实测变形相比较。发现两种混合料高温变形发展规律以及对不同荷载条件的响应方式不同,SMA具有优异的高温抗变形能力;有限元模拟的误差约为10%。分析结果表明:采用三轴重复加载试验和多元线性回归确定材料的非线性计算模型参数的方法可靠,模型参数可用于沥青桥面铺装的车辙变形预估。     

突缘叉模锻件折叠缺陷分析

通过对缺陷的内部结构进行分析,发现突缘叉锻件法兰底面产生缺陷的主要原因是模锻前制坯工艺不合理,造成模锻时金属回流,产生折叠.提出改进制坯工艺消除锻件的缺陷的方案,经工艺和生产验证,消除了锻件缺陷,提高了锻件质量,取得满意效果,该工艺的成功应用,可为同类型产品的生产提供借鉴.     

风和随机车流下悬索桥伸缩缝纵向变形

为动态仿真与评估运营阶段风和随机车流联合作用下大跨钢桁悬索桥伸缩缝纵向变形, 建立了风-随机车流-钢桁悬索桥分析系统; 基于已有单主梁风-车-桥耦合振动分析系统, 引入弹簧单元模拟伸缩缝, 并从车-桥耦合关系和钢桁梁横断面风荷载精细化加载2个方面将分析系统从单主梁提升为梁格法; 基于监测数据仿真重现了交通流荷载, 采用建立的分析系统计算了一座典型大跨钢桁悬索桥伸缩缝在随机车流作用下的动态位移时程响应, 获取并验证了累计位移与交通流质量的相关关系; 以滑动支承耐磨材料厚度为评估指标确定了伸缩缝累计位移临界值, 评估了伸缩缝的正常工作寿命; 在不同风速和随机车流作用下对伸缩缝纵向变形性能进行了参数敏感性分析。分析结果表明: 伸缩缝在随机车流作用下的时位移极值远小于设计允许伸缩范围-880~880 mm; 伸缩缝累计位移与其对应时段内的交通流荷载具有正相关性; 在风与随机车流联合作用下, 风速小于15 m·s-1时, 影响伸缩缝纵向变形的主要荷载因素为随机车流, 风速大于15 m·s-1时, 主要荷载因素为风荷载; 伸缩缝时位移极值与时累计位移随风速的增大均呈增大趋势; 当风速增大至20 m·s-1时, 风荷载产生的伸缩缝纵向变形近似为车流荷载下的2倍; 建立的风-随机车流-钢桁悬索桥分析系统可为运营荷载下伸缩缝纵向变形的动态仿真与性能评估提供数值分析平台。      

Flow stress model of stainless steel 0Cr13Ni5Mo at elevated temperature

For a more accurate forming calculation and numerical simulation of hydraulic turbine blade, experimental studies on the flow stress of stainless steel 0Cr13Ni5Mo were carried out upon Gleeble-1500 thermal simulator under different deformation conditions.The results then were analyzed and the effects of all influencing factors were summarized consequently.New mathematic models were conceived.Utilizing the software Matlab, regression coefficients were calculated by the least square method.The model has an eminent capability of curve-fitting performance with impact structure whose correlation coefficient is up to 0.9080 and the cosine coefficient is 0.9958.All mathematic models and process parameters can be used in engineering calculations or computer simulations.     

金属挤压成型的数值模拟技术研究

对于许多加工过程中的接触问题，要想得到一个合理的结果一直比较困难，这是因为，在这些加工过程中，工件在产生变形的同时往往伴随着温度的变化。温度与位移两种不同场变量之间存在很强相互作用（即热－机耦合）。应用大型有限元程序MARC成功地对金属挤压成型过程进行了数值模拟，计算结果经分析，认为是合理的，此结果可用于算例分析，也可为进行结构设计人员提供设计参考。