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文章采用旋压工艺替代传统机加工工艺成形多楔带轮。针对物理实验中产生的旋压裂缝以及飞边缺陷,运用有限元模拟分析了变形区域的材料流动情况、应力分布以及缺陷的形成机理。结果表明,多楔带轮在增厚成形过程中,其端部区的材料流动速度低于口部区的材料流动速度,造成端部区的材料积累,形成飞边;在端部与侧壁相交处出现材料不足,径向、周向、轴向最大应力值均超过材料抗拉强度,导致产生旋压裂缝。通过增加一个凹形预成形旋轮,对旋压工艺进行改进,在CDC-S80旋压机上进行试验,消除了旋压裂缝以及飞边缺陷。
The article uses the spinning process instead of the traditional machining process forming ribbed pulley. Aiming at the spinning cracks and flash defects in physical experiments, the flow field, stress distribution and defect formation mechanism in deformation area were analyzed by finite element method. The results show that during the thickened forming process, the material flow velocity in the end region is lower than that in the mouth region, resulting in the accumulation of material in the end region to form the flash; at the end and the side wall There was not enough material at the intersection, and the maximum radial, circumferential and axial stress exceeded the tensile strength of the material, resulting in the occurrence of spinning fractures. The spinning process was improved by adding a concave pre-formed roller, which was tested on a CDC-S80 spinning machine to eliminate spinning cracks and flash defects.