王广春
金属塑性成形数值模拟以及快速成形与快速模具制造技术
个性化签名
- 姓名:王广春
- 目前身份:
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学术头衔:
博士生导师
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学科领域:
材料合成与加工工艺
- 研究兴趣:金属塑性成形数值模拟以及快速成形与快速模具制造技术
王广春教授,中国机械工程学会青年学术委员会委员,塑性工程学会青年工作学术委员会委员,机械科学研究院机电产品开发与创新学术中心高级研究员。申请者长期以来一直致力于金属塑性成形数值模拟以及快速成形与快速模具制造技术的研究工作,承担并完成了多项国家以及省部级课题工作,发表了大量学术论文,其中被SCI、EI收录近30篇。获得教育部科技进步一等奖2项,获得山东省十大科技成果奖1项,获得山东省科技进步二等奖奖2项。出版学术专著1部,参编大型手册4册。主持完成数十项企业技术支持与服务课题。
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王广春
材料科学与工艺,1997,5(3):1~4,-0001,():
-1年11月30日
在300KN摆辗机上对国内粉末台金制品中常用的Fe-Cu-C烧结体进行了自由摆辗镦粗实验。实验结果表明,粉末烧结体在摆辗过程中的成形性能较低。通过测定烧结体在辗压破坏前的高度方向压缩率和径向扩展比,得出了在摆辗过程中烧结体的高径比和初始密度对自由镦粗变形的影响规律,并对实验数据进行了回归处理。
粉末烧结体, 摆动辗压, 成形性能
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【期刊论文】基于变形均匀性的锻造过程微观组织优化方法及其应用*
王广春, 赵国群, 赵新海, 马新武, 管婧, 李玲
,-0001,():
-1年11月30日
在中国国家自然科学基金项目《锻造成形微观组织优化方法研究及应用》资助下,为提供一种控制锻造成形制品微观晶粒尺寸的理论方法和途径,开展基于变形均匀性的锻造过程微观组织优化研究。 认为,锻造生产除保证产品的基本形状要求,更重要的是通过材料的塑性变形提高产品的综合机械性能。因此,金属塑性成形过程微观组织模拟与优化研究具有应用价值。 在描述金属在高温塑性变形中组织变化机制基础上,提出材料在热锻成形过程中动态再结晶、静态再结晶,以及晶粒长大等微观组织演变机理。金属塑性变形是以位错运动来实现的,随着变形的进行,位错密度不断增加,高位错密度聚集的能量使材料处于不稳定状态。对于低层错能金属(碳钢)的热塑性变形,因其动态恢复缓慢而不能充分消除高密度层错能。动态恢复之后紧接着会出现动态再结晶现象。未能经过动态恢复和动态再结晶充分软化的金属停止变形后,其组织将发生静态再结晶。再结晶过程完成后的新组织是亚稳定的,为获得更稳定的组织,需要释放晶粒内部的潜能。因此,再结晶完成后,要发生进一步的晶粒长大来减少单位体积内的晶界面积。 认为锻造过程的变形均匀性对微观组织具有重要影响。锻造过程中存在着变形场、应力场、应变场,以及温度场的变化,这些场量的综合作用决定了变形体变形的均匀程度。从锻造过程微观组织演变过程看,无论是动态再结晶、静态再结晶,还是晶粒的长大,其晶粒尺寸的变化除了与材料特定的特性参数以外,都是应变速率、应变和温度的函数,即晶粒尺寸直接决定于变形过程中的应变场、应变速率场,以及温度场。锻件变形越均匀,整个变形体内部的应变场、应变速率场以及温度场等的分布也越均匀,其晶粒组织也越趋于一致。 对与锻造过程变形均匀性相关的指标进行数学描述,包括应变梯度的定义及其数学描述,任意应变与平均等效应变差的平方和的定义及其数学描述。为有效衡量变形均匀程度,提出变形均匀因子的概念和定义,给出变形均匀性因子的物理含义和数学表达。 以变形均匀性为基础,给出形状控制子目标函数、温度均匀性子目标函数、变形均匀性子目标函数,以及晶粒度细小均匀子目标函数的数学定义,并通过无量纲化处理构建出实现形状控制和微观组织晶粒度细小均匀的多目标函数。 以材料高温成形微观组织演变机理为基础,与刚塑性有限元热力耦合数值模拟技术相结合,以锻造过程工艺参数及预成形模具形状作为优化设计变量,以变形均匀性和微观组织晶粒度细小均匀为优化目标,建立锻造成形过程微观组织优化体系,开发出基于微观遗传算法和灵敏度分析方法的锻造过程微观组织优化软件系统(MOSForge)。 利用MOSForge,进行典型热镦粗和H 型锻件锻造工艺参数和锻造预成形模具形状的优化实验,实现锻造过程微观组织晶粒度细小均匀控制。平板热镦粗工艺参数优化使平均晶粒尺寸下降20µm;结合预成形形状的优化,热镦粗成形的平均晶粒度下降66µm;H 型锻件预成形模具形状的优化,使得平均晶粒尺寸下降25.2 µm。上述实例应用中不但晶粒尺寸得到细化,而且晶粒度的分布均匀程度也得到明显提高。
锻造 微观组织 优化 预成形 变形均匀性 微观遗传算法 灵敏度分析方法 数值模拟
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王广春, Wang Guangchun*, Zhao Guoqun
Journal of Materials Processing Technology 95(1999)112-115,-0001,():
-1年11月30日
The deformation of a ring workpiece by the rotary forging process is analyzed using a three-dimensional rigid
Ring workpiece, Rotary forging, Deformation analysis, FEM
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【期刊论文】Densif ication laws and properties of sintered powder compacts in rotary forging process①
王广春, WANG Guang-chun, ZHAO Guo-qun, JIA Yu-xi, YANG Yan
Trans. Nonferrous Met. Soc. China, 2000, 10 (1): 1~4,-0001,():
-1年11月30日
In order to obtain high property powder metallurgy products, at present rotary forging process has often been used to further densify the sintered powder compact, but the densification law and property analysis have very rarely been studied, therefore the densification laws of sintered powder compacts being composed of Fe-0.8%C-4.0%Cu-0.2% zinc stearate and formed as cylindrical shape by double action pressing, and then further densified as well in a rotary forging process was studied by orthogonal experiment and regression analysis. The experimental results show that the H/D ratio and the rotary forging force are major factors affecting the density of the sintered powder compacts in the rotary forging process. The effect of the H/D ratio and the rotary forging force on the density were discovered. By determining both the density and the hardness of compacts, it was found that the density distributions show no difference from the hardness dis-tributions and that the gradients of the density and the hardness in the axial direction are larger than those in the radial di-rection.
sintering powder compact, rotary forging, densification, mechanical properties
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王广春, G. -C. Wang*, G. -Q. Zhao, X. -H. Huang, Y. -X. Jia
Journal of Materials Processing Technology 121(2002)259-264,-0001,():
-1年11月30日
The support shaft is a key part in the automobile industry. Its annual production quantity is usually very large. The current manufacturing process is conducted with much machining work including drilling the hollow, which results in a great waste of material. This paper gives a new manufacturing method by the implementation of extrusion processes. It can not only save much material but can also improve properties of the support shaft. The new manufacturing processes include a two-stage extrusion process. A reasonable preform shape was determined through finite element based simulation. Thewhole forming process is simulated and verified by the finite element method using the DEFORMTM system. The die designs of the two extrusion processes are also given. The two-stage extrusion process and related die designs were recommended to one forging company that presently manufactures the support shaft with the traditional method.
Support shaft, Extrusion process, Finite element method
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【期刊论文】Simulation and analysis of rotary forging a ring workpiece using finite element method
王广春, Wang Guangchun*, Zhao Guoqun
Finite Elements in Analysis and Design 38(2002)1151-1164,-0001,():
-1年11月30日
The methods of dealing with some key problems in analyzing a rotary forging process with a finite element method are given. The presented mechanical model of the finite element analysis is in accordance with the actual conditions of the rotary forging process. A three-dimensional rigid–plastic finite element analysis code is developed in FORTRAN language and used to analyze the rotary forging process of a ring workpiece. Velocity fields and stress-strain fields of both contact and non-contact zones of the ring workpiece in the rotary forging are obtained. The deformation mechanism and metal flow laws of the contact zone surface of the ring workpiece in the rotary forging process are revealed. The pressure distributions of the contact surface along the radial and tangential directions and effects of rotary forging parameters on deformation characteristics are given.
Metal forming, Finite element method, Rotary forging, Ring workpiece
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【期刊论文】Numerical and experimental study on new cold precision forging technique of spur gears①
王广春, WANG Guang-chun, ZHAO Guo-qun, XIA Shi-sheng, LUAN Yi-guo
Trans. Nonferrous Met. Soc. China, 2003, 13 (4): 1~5 ,-0001,():
-1年11月30日
A new cold precision forging technique is proposed to form a spur gear from a hollow billet, that is blocking the divided flow region and then final forging by the relief hole. 3D2FEM simulation of the whole process of a pure alu-minium spur gear is performed using DEFORM-3DTM. The load-stroke curve, effective stress distribution, effective strain distribution, velocity distribution, and so on, are achieved. These results are compared with those achieved using the conventional closed die forging in the same conditions. The results show that this new technique has many advantages over the conventional one. The deformation load is reduced by near 30% and the filling ability of the tooth profile is also improved. Precision forging experiments of spur gears with the new process were performed using material Pb. The experimental results show a good agreement with the numerical results.
spur gear, cold precision forging, numerical simulation
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【期刊论文】Rapid Design and Manufacturing System of the Product and Its Applications
王广春, Wang Guangchun*, Li Huiping, Guan Yanjin, Zhao Guoqun
,-0001,():
-1年11月30日
In recent years, rapid prototyping(RP) and rapid tooling(RT) technologies have been implemented in many aspects of industry, especially in the area of new product development. Based on RP and RT technologies, a rapid design and manufacturing system of the product was proposed in this paper. From two ways of a concept or a sample to the final product design, a reverse engineering technology, transmission processing software or modules of the input data, structure analysis and optimization means and manufacturing process analysis tools were integrated in the system. Some examples of applications show that the integrated system not only can reduce the numbers of design iterations but also improve the efficiency and reliability of the product design.
Product development, Rapid prototyping, Rapid tooling, Integrated system
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王广春, 赵国群, 夏世升
,-0001,():
-1年11月30日
与精锻成形工艺相比,传统的切削加工方法加工直齿轮具有诸多弊端,而当前提出的闭式镦挤成形工艺载荷过大,严重制约着精密成形直齿轮工艺的实用化。本文提出采用预锻分流区—分流终锻新工艺精密成形直齿圆柱齿轮,设计了能够进行多种组合的精锻成形实验模具,并对空心管坯和实心圆柱坯进行了传统的闭式镦挤和新的分流成形工艺实验,实验结果表明:与传统的闭式镦挤和现有的圆柱直齿轮成形工艺对比,本文提出的成形工艺工序简单,终锻后齿形充填饱满,端面平整,而且成形载荷降低了37%以上,具有生产实用化的前景。
直齿轮, 精锻成形工艺, 实验研究
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【期刊论文】金属塑性成形过程的微观组织模拟与优化技术研究现状*
王广春, 管婧, 马新武, 赵国群
塑性工程学报,2002,9(1):1~5,-0001,():
-1年11月30日
介绍了金属塑性成形过程中微观组织演变的数学模型和常用的微观组织优化目标函数,给出了金属塑性成形微观组织模拟和优化的主要方法——微观遗传算法和灵敏度分析方法的基本原理,叙述了近年来国内外金属塑性成形微观组织模拟与优化研究概况。
金属塑性成形, 微观组织演变, 数值模拟与优化
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