CN-121980682-A - Full-flow digital design and performance prediction method for forging and rolling wheels with complex structures

CN121980682ACN 121980682 ACN121980682 ACN 121980682ACN-121980682-A

Abstract

The invention discloses a full-flow digital design and performance prediction method for forging and rolling wheels with complex structures, and belongs to the technical field of metal plastic forming and digital simulation. Aiming at the defects of the existing method, an integrated forming module is designed, a parameterized modeling method is provided, three-dimensional modeling and assembly of all molds and blanks are automatically completed by accessing wheel parameters in an Access database based on Visual Basic and SolidWorks secondary development, a tissue performance prediction method is provided, the parameterized model is automatically imported into finite element software, and macro-micro coupling calculation is carried out by secondarily developing and integrating a micro-tissue model and a cellular automaton, so that micro-tissue distribution after wheel forming is predicted. The invention realizes full-flow digitization and automation from wheel design parameter input to final organization performance prediction, obviously improves the research and development efficiency and forming quality prediction precision of the wheels with complex structures, and provides core technical support for optimizing and manufacturing key components of rail transit.

Inventors

LI WEI
ZHAO JIKANG
MA CHUANCHUAN
XUE CHUN
LI ZHENJIANG

Assignees

太原科技大学

Dates

Publication Date: 20260505
Application Date: 20260116

Claims (9)

1. The full-flow digital design and performance prediction method for the wheel forging and rolling of the complex structure is characterized by comprising the following steps of: The method comprises the steps of constructing a wheel forging-rolling integrated forming multi-scale digital simulation platform comprising a forming system development module, a parameterization modeling module and a tissue performance prediction module, inputting design parameters of a wheel with a complex structure into the forming module and the parameterization modeling module in the wheel forging-rolling integrated forming multi-scale digital simulation platform, and obtaining a die required by a forging-rolling forming macroscopic-microscopic coupling model; The method comprises the steps of inputting stress strain data and microstructure state variables of materials under different temperatures, different strain rates and different deformation amounts obtained through a thermal compression experiment into a microstructure performance prediction module in a wheel forging-rolling integrated forming multi-scale digital simulation platform, and realizing microstructure evolution process performance prediction of local different positions in the wheel pre-forging forming, final forging forming and rolling forming processes.
2. The full-flow digital design and performance prediction method for wheel forging and rolling with the complex structure is characterized by comprising the specific steps of developing a parameterized design interface of an integrated forging sub-module and a rolling sub-module based on a Visual Basic platform, developing a main control program framework, adopting a GUI interface design to realize paging switching and parallel operation of the forging and rolling modules, creating a unified parameter input panel, setting a process stage selection page comprising pre-forging, final-forging and rolling, and realizing dynamic loading and display of process related parameters; The parameterized modeling module comprises the specific steps of developing a parameterized design interface of an integrated forging and rolling subsystem based on a Visual Basic platform, establishing an Access database for storing wheel design parameters, utilizing Solidworks software for secondary development, calling an API interface function, and realizing automatic three-dimensional modeling and procedure assembly of all dies and blanks according to database parameters; The tissue performance prediction module comprises the specific steps of automatically importing a model obtained by three-dimensional modeling into finite element software, constructing a forging-rolling forming finite element model, completing model assembly, grid division, material definition and process parameter and boundary condition setting through secondary development of the finite element software, performing secondary development in the finite element software, integrating a microstructure evolution model through a user subroutine in the finite element software, combining a cellular automaton model, performing coupling calculation of macroscopic deformation and microstructure evolution, calculating and updating microstructure state variables of a wheel blank in real time, integrating the forging-rolling forming finite element model, the microstructure evolution model and the cellular automaton model, establishing a forging-rolling forming macroscopic-microscopic coupling model, and predicting microstructure distribution after wheel forming based on coupling calculation results based on the obtained macroscopic stress strain data.
3. The full-process digital design and performance prediction method for wheel forging and rolling with the complex structure according to claim 2 is characterized in that the forging module comprises a pre-forging upper/lower die, a final-forging upper/lower die and corresponding blanks, and the rolling module comprises a main roller, a pressing roller, a web roller and corresponding blanks.
4. A complex-structured wheel forging full-process digital design and performance prediction method according to claim 3, wherein the wheel design parameters include wheel blank diameter, rim height, spoke thickness, hub aperture, tread profile curve and roller mold line.
5. The full-process digital design and performance prediction method for wheel forging and rolling with complex structure according to claim 4, wherein the forging-rolling forming finite element model comprises a pre-forging finite element model, a final-forging finite element model and a rolling finite element model.
6. The method for full-process digital design and performance prediction of complex-structured wheel forging and rolling according to claim 5, wherein the microstructure evolution model comprises a dislocation density evolution model, a nucleation rate model, a grain growth model and a dynamic recrystallization model, and the coupling calculation is realized through a user-defined subroutine interface of finite element software.
7. The full-process digital design and performance prediction method for complex-structured wheel forging as set forth in claim 6, wherein said microstructure state variables comprise average grain size and recrystallized volume fraction.
8. The method for fully-process digital design and performance prediction of wheel forging and rolling with complex structure according to claim 7, wherein the forging-rolling forming macro-micro coupling model is realized by finite element simulation software DEFORM and ABAQUS coupling cellular automata, and parameters input by the forging-rolling forming macro-micro coupling model are stress, strain rate, temperature, grain size and recrystallization percentage secondarily developed by adopting Fortran language.
9. The full-process digital design and performance prediction method for wheel forging and rolling with complex structure according to claim 6, wherein the dislocation density evolution model is as follows: In the formula, In the event of a stress being applied to the substrate, Is a constant value, and is used for the treatment of the skin, In order to be an average dislocation density, In order to achieve a shear modulus, the polymer is, Is a berkovich vector; In the formula, For strain, k 1 is the work hardening coefficient, k 2 is the dynamic softening coefficient, Average dislocation density as a cell; The nucleation rate model is as follows: In the formula, C and m are material parameters and are constants; the grain growth model is as follows: In the formula, And Respectively are crystal grains The growth speed and the driving force are controlled, Is mobility; The dynamic recrystallization model is as follows: In the middle of Indicating that the grain i is poorly oriented, Is the energy of the grain boundary, For a large angle grain boundary orientation difference, 15 ° was taken. In the formula, Is poisson's ratio; In the formula, Is a constant; In the middle of For the mobility of the grain boundaries, Is the grain boundary thickness, Is the self-diffusion coefficient of the grain boundary, As a result of the boltzmann constant, The activation energy is for grain boundary diffusion.

Description

Full-flow digital design and performance prediction method for forging and rolling wheels with complex structures Technical Field The invention belongs to the technical field of metal plastic forming and digital simulation, and particularly relates to a full-flow digital design and performance prediction method for forging and rolling of wheels with complex structures. Background Wheels with complex structures (such as wheels of high-speed trains) are key bearing parts of rail traffic equipment, and the internal organization and mechanical properties of the wheels are directly related to operation safety and service life. At present, the wheel is commonly formed by an integrated forming process of forging and rolling. However, the process is complex, involves multiple steps, large deformations, high temperature unsteady processes, and has highly nonlinear coupling between the process parameters (e.g., die shape, reduction, rolling speed, friction conditions, etc.) and the microstructure (e.g., grain size, phase composition) and macroscopic properties (e.g., strength, toughness, fatigue life) of the final workpiece. The prior art has the following defects: The modeling efficiency is low, the traditional finite element modeling method depends on manual operation, and aims at wheel blanks or process adjustment with different specifications, geometric models are required to be re-established, grids are divided, boundary conditions are required to be set, the process is tedious, the period is long, and quick process analysis and optimization are difficult to realize. Process and performance disjoints-existing simulation analysis is mostly focused on stress, strain, temperature field analysis of the forming process, but lacks direct, accurate correlation with microstructure evolution (e.g., dynamic/static recrystallization, grain growth). The final performance index of the wheel is difficult to be directly predicted by process designers according to the simulation result, and expensive trial production and destructive detection are still needed. The lack of systematic integration, i.e. the simulation of each process step such as forging, rolling and the like is often isolated, a digital twin model of full-flow and seamless connection from blank to finished product cannot be formed, and the genetic influence of the former process step on the latter process step (such as the non-uniformity of tissues caused by preforming) cannot be accurately reflected. Therefore, the method capable of fast modeling, accurately simulating and realizing the tissue performance integrated prediction is designed, and has important significance for improving the manufacturing level of the wheel with the complex structure, shortening the research and development period and guaranteeing the product quality. Disclosure of Invention Aiming at the problems of low modeling efficiency, disjointed process and performance and lack of systematic integration of the existing method, the invention provides a full-flow digital design and performance prediction method for wheel forging and rolling with a complex structure, which realizes the rapid construction of a model through parameterized driving and the accurate prediction of the full-flow forming history and final performance of the wheel through integrating multiple physical field simulation and tissue evolution models. In order to achieve the above purpose, the present invention adopts the following technical scheme: a full-flow digital design and performance prediction method for forging and rolling wheels with complex structures comprises the following steps: the method comprises the steps of constructing a wheel forging-rolling integrated multi-scale digital simulation platform comprising a forming system development module, a parametric modeling module and a tissue performance prediction module, inputting characteristic dimension design parameters of a wheel with a complex structure into the forming module and the parametric modeling module in the wheel forging-rolling integrated multi-scale digital simulation platform, and obtaining a die required by a forging-rolling forming macroscopic-microscopic coupling model; The method comprises the steps of inputting stress strain data and microstructure state variables of materials under different temperatures, different strain rates and different deformation amounts obtained through a thermal compression experiment into a microstructure performance prediction module in a wheel forging-rolling integrated forming multi-scale digital simulation platform, and realizing microstructure evolution process performance prediction of local different positions in the wheel pre-forging forming, final forging forming and rolling forming processes. The forming system development module comprises a parameterized design interface for developing an integrated forging sub-module and a rolling sub-module based on a Visual Basic platform, a main control program fram