The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.T...The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.展开更多
The development and research of titanium cast alloy and its casting technology, especially its application in aeronautical industry in China are presented. The technology of molding, melting and casting of titanium al...The development and research of titanium cast alloy and its casting technology, especially its application in aeronautical industry in China are presented. The technology of molding, melting and casting of titanium alloy, casting quality control are introduced. The existing problems and development trend in titanium alloy casting technology are also discussed.展开更多
Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forgin...Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forging is difficult to control. Many simulations and analysis of precision forging process were taken by previous researchers. But no concrete method is proposed to evaluate and optimize the forming quality of half axel gears. The primary purpose of this work is improving the forming quality of half axel gears by analyzing and optimizing the affected factors of forming quality. The enclosed-die warm forging process of half axle gears was developed, and a new type of die-set used on double action hydraulic press was brought forward. The main influential factors of precision forming quality were analyzed after the forming process had been simulated by using finite element method（FEM）. These factors include die structure, web thickness and web position. A method used to evaluate the forming quality was established, which investigated the maximal forming load, the metal filling rate and the material damage factor. The FEM simulations of half axle gears precision forging were evaluated by this method. The results show that the best forming quality can be achieved when the punches were added with bosses, the web located at the middle plant of the gear, and the web thickness was 30 percent of the inner hole diameter. Verification experiments taking the above optimized parameters were performed on a 7.8 MN double action hydraulic press. The trial products were formed well. And their geometric precision meets the demand. The verification result shows that the optimization of the influential factors, according to the simulations and the evaluation method, can improve the forming quality. The new structure of precision forging die-set and the new evaluation method guarantee a high forming quality ofhalfaxel gears.展开更多
As one of the indispensable actuating components in micro-systems,the shafted microgear is in great production demand.Microforming is a manufacturing process to produce microgears to meet the needs.Due to the small ge...As one of the indispensable actuating components in micro-systems,the shafted microgear is in great production demand.Microforming is a manufacturing process to produce microgears to meet the needs.Due to the small geometrical size,there are uncertain process performance and product quality issues in this production process.In this study,the shafted microgears were fabricated in two different scaling factors with four grain sizes using a progressively extrusion-blanking method.To explore the unknown of the process,grain-based modeling was proposed and employed to simulate the entire forming process.The results show that when the grains are large,the anisotropy of single grains has an obvious size effect on the forming behavior and process performance;and the produced geometries and surface quality are worsened;and the deformation load is decreased.Five deformation zones were identified in the microstructures with different hardness and distributions of stress and strain.The simulation by using the proposed model successfully predicted the formation of zones and revealed the inhomogeneous deformation in the forming process.The undesirable geometries of microgears including material unfilling,burr and inclination were observed on the shaft and teeth of gear,and the inclination size is increased obviously with grain size.To avoid the formation of inclination and material unfilling,the punch was redesigned,and a die insert was added to constraint the bottom surface of the gear teeth.The new products had then the better forming quality.展开更多
基金Founded by the National Key Technology R&D Program in the 11th Five Year Plan of China(2007BAE38B00)
文摘The effects of die structure such as the height of the welding,the welding angle and chamber the shape of the bridge on the welding quality of profiles were investigated by means of the commercial software DEFORM-3D.The numerical simulation results show that the welding quality of the hollow profiles has great sensitive to the die structure.With increasing the welding chamber height and decreasing the welding angle of the die leg can improve the welding quality.In addition,the welding quality index k of the new designed shape of the die leg is little down from 4.1 to 3.9 comparing the standard leg.
基金The paper is support by Foundation Key Project of Yunnan:The Study on inoculated theory and reliability of low carbonductile iron, NO. 1999E0004Z
文摘The development and research of titanium cast alloy and its casting technology, especially its application in aeronautical industry in China are presented. The technology of molding, melting and casting of titanium alloy, casting quality control are introduced. The existing problems and development trend in titanium alloy casting technology are also discussed.
基金supported by Chongqing Municipal Science and Technology Committee of China (Grant No. 2005AA3012-4)
文摘Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forging is difficult to control. Many simulations and analysis of precision forging process were taken by previous researchers. But no concrete method is proposed to evaluate and optimize the forming quality of half axel gears. The primary purpose of this work is improving the forming quality of half axel gears by analyzing and optimizing the affected factors of forming quality. The enclosed-die warm forging process of half axle gears was developed, and a new type of die-set used on double action hydraulic press was brought forward. The main influential factors of precision forming quality were analyzed after the forming process had been simulated by using finite element method（FEM）. These factors include die structure, web thickness and web position. A method used to evaluate the forming quality was established, which investigated the maximal forming load, the metal filling rate and the material damage factor. The FEM simulations of half axle gears precision forging were evaluated by this method. The results show that the best forming quality can be achieved when the punches were added with bosses, the web located at the middle plant of the gear, and the web thickness was 30 percent of the inner hole diameter. Verification experiments taking the above optimized parameters were performed on a 7.8 MN double action hydraulic press. The trial products were formed well. And their geometric precision meets the demand. The verification result shows that the optimization of the influential factors, according to the simulations and the evaluation method, can improve the forming quality. The new structure of precision forging die-set and the new evaluation method guarantee a high forming quality ofhalfaxel gears.
基金The authors would like to acknowledge the funding support to this research from the projects of ZE1W and BBAT from The Hong Kong Polytechnic University,the National Natural Science Foundation of China(NSFC)(Grant No.51835011)the General Research Fund(GRF)(Grant No.15223520).
文摘As one of the indispensable actuating components in micro-systems,the shafted microgear is in great production demand.Microforming is a manufacturing process to produce microgears to meet the needs.Due to the small geometrical size,there are uncertain process performance and product quality issues in this production process.In this study,the shafted microgears were fabricated in two different scaling factors with four grain sizes using a progressively extrusion-blanking method.To explore the unknown of the process,grain-based modeling was proposed and employed to simulate the entire forming process.The results show that when the grains are large,the anisotropy of single grains has an obvious size effect on the forming behavior and process performance;and the produced geometries and surface quality are worsened;and the deformation load is decreased.Five deformation zones were identified in the microstructures with different hardness and distributions of stress and strain.The simulation by using the proposed model successfully predicted the formation of zones and revealed the inhomogeneous deformation in the forming process.The undesirable geometries of microgears including material unfilling,burr and inclination were observed on the shaft and teeth of gear,and the inclination size is increased obviously with grain size.To avoid the formation of inclination and material unfilling,the punch was redesigned,and a die insert was added to constraint the bottom surface of the gear teeth.The new products had then the better forming quality.
