铝杆连铸结晶轮滚压残余应力数值仿真与工艺参数优化.pdf

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1、JournalofMechanicalStrength机械度铝杆连铸结晶轮滚压残余应力数值仿真与工艺参数优化PRoCESSPARAMETERoPTIMIZATIoNANDNUMERICALSIMULATIoNOFSURFACERoLLINGRESIDUALSTRESSESINCRYSTALLIZINGWHEELUSEDFoRALUMINUMRoD王栋。韩变枝王忠文(1．太原理工大学阳泉学院，阳泉045000)(2．阳泉铝业股份有限公司，阳泉045002)WANGDongHANBianZhiWANGZhongWen(1．YangquanCollege，Tai

2、yuanUniversityofTechnology，Yangquan045000，China)(2．ShanxiYangquanAluminumCo．Ltd．，Yangquan045002，China)摘要表面滚压技术可有效提高金属零件的疲劳强度，借助于有限元数值仿真可以分析、优化滚压工艺基本参数。以电工铝杆连铸结晶轮为研究对象，设计了滚压方案，建立了连续多圈滚压的数值仿真模型，获得了合理的滚压变形与残余应力结果，并分析了滚压参数对残余应力分布规律的影响。仿真结果显示，滚压进给量太大、转速太快都容易造成表层残余应力分布的不均匀甚至产生残余拉应力；合理的滚

3、压圈数在于稳定和保持已经获得的残余压应力，获得较高的表面质量。仿真参数为结晶轮的滚压工艺制订／优化提供重要的指导／参考价值，数值仿真的优化参数经过生产实践验证，达到了显著提高抗疲劳强度和使用寿命的效果。关键词结晶轮滚压残余应力数值仿真参数优化中图分类号TG233．6AbstractItisveryeffectiveontheimprovementoffatiguestrengthofcomponentsbysurfacerolling．WiththeaidofFEsimulationandanalysis，thebasicprocessparameters

4、ofthesurfacerollingcanbeanalyzedandoptimized．Inthispaper，therollingplanwasfirstlydesignedforthealuminumrodcrystallizingwhee1．Thenthenumericalsimulation3Dmodelwasestablishedforringrolling，therollingdeformationresultsandresidualstressesobtainedwerereasonable．Theinfluencesofrollingpa

5、rametersonthedistributionrulesofresidualstresswerediscussed．Theresultsindicatethat，toobigfeedingortoofastrollingspeedmayeasilycausethesurfaceresidualstressdistributionuneven，orevenresuhintensileresidualstress；thenumberofrollingringsplaysaneffectiveroletokeepthereasonableobtainedre

6、sidualcompressivestressstable，andtoobtainhighsurfacequality．Thesimulationparametersprovidedforrollingprocessofthecrystallizingwhee1．Ithasimportantguidingandreferencevalue．Thesimulationprocesswasverifiedbytheproductionpractice，itwastoachieveexpectedresultstoimprovethefatiguestrengt

7、handservicelife．KeywordsCrystallizingwheel；Surfacerolling；Residualstress；Numericalsimulation；ParameteroptimizationCorrespondingauthor：WANGDong，E—mail：meizhuanwang@163．corn，Tel：+86—353—6662265Manuscriptreceived20l30502，inrevisedform20130812．影响生产的顺利进行。表面滚压技术是对零件表层金引言属材料加压，使金属原子间距离发生

8、变化，当压力达到结晶轮是电工圆铝杆连铸连轧生产线中连续铸造一定数值