CN-121980857-A - Wheel forging and rolling composite forming process and structure regulating and controlling method based on deformation distribution

CN121980857ACN 121980857 ACN121980857 ACN 121980857ACN-121980857-A

Abstract

The invention discloses a wheel forging and rolling composite forming process and a tissue regulating and controlling method based on deformation distribution, and belongs to the technical field of wheel manufacturing. The method comprises the steps of adopting a composite forming path of 'pre-forging, final forging and finish rolling', and scientifically distributing deformation of each working procedure, wherein the pre-forging accounts for 70% -80%, the final forging accounts for 15% -20%, and the finish rolling accounts for 5% -10%, so that forming precision and microstructure control are realized. Meanwhile, quantitatively predicting the microstructure evolution of the whole forming process by constructing a multi-scale digital simulation platform of an integrated material constitutive model, a microstructure evolution model and a cellular automaton. Based on the prediction result, the active and accurate regulation and control of the microstructure of different parts of the wheel are realized by optimizing key process parameters such as temperature, deformation, strain rate and the like through virtual iteration, and finally the wheel with the complex structure is obtained, wherein the dimensional accuracy is high, the structure is uniform and fine, and the comprehensive performance is excellent. The invention realizes the cooperative manufacturing of the wheel shape and performance, and improves the scientificity and efficiency of process design.

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 (10)

1. The wheel forging and rolling composite forming process and the microstructure control method based on deformation distribution are characterized by comprising the forging and rolling composite forming process and microstructure control, wherein: The forging and rolling composite forming process comprises the following steps: Pre-forging, namely pre-forging the blank heated to the forging temperature to drive the metal to deform axially for preliminarily forming the shape profile of the outer hub surface and the web of the wheel; Finish forging forming, namely, finish forging the pre-forged blank, and driving the metal to axially deform so as to form the shape contours of an outer wheel hub surface, an inner wheel hub surface, a radial plate, an outer wheel rim surface and an inner wheel rim surface of the wheel; finish rolling and forming, namely finish rolling the final-forged wheel blank, driving the metal to radially deform, and precisely forming a wheel web, an outer rim surface, an inner rim surface, a tread and a rim; The microstructure modulation includes: Constructing a forging-rolling forming finite element model based on a composite forming process, and finishing the assembly, grid division, material definition, process parameter and boundary condition setting of the forging-rolling forming finite element model through secondary development of finite element software; Performing secondary development in a forging-rolling forming finite element model, integrating a microstructure evolution model through a user subroutine, and performing coupling calculation of macroscopic deformation and microstructure evolution by combining a cellular automaton model, and calculating and updating microstructure state variables of a formed wheel in real time; 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, so as to realize microstructure evolution process performance prediction of local different positions in the wheel pre-forging forming, final forging forming and rolling forming processes; Based on the prediction result, the optimal process window meeting the target tissue performance is determined by optimizing the temperature, deformation distribution and strain rate parameters of each process through virtual iteration, physical trial production is carried out according to the optimal process window, and model parameters are corrected through comparison of the detection result and the prediction result of the physical trial production, so that closed-loop regulation and control are formed.
2. The wheel forging and rolling composite forming process and the organization regulation method based on deformation distribution, which are disclosed in claim 1, are characterized in that the forming system development module comprises 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 wheel forging and rolling composite forming process and the tissue regulating and controlling method based on deformation distribution according to claim 2, wherein the shape profile of the wheel is a hub, a web, a rim, a tread and a rim, the hub is divided into an outer hub surface and an inner hub surface, the rim is divided into an outer rim surface and an inner rim surface, the hub height is L g , the outer hub height is L gw , the inner hub height is L gn , the web height is L f , the outer rim height is L ww , the inner rim height is L wn and the rim outer diameter is d f .
4. The wheel forging and rolling composite forming process and the structure regulating and controlling method based on deformation distribution are characterized in that the deformation of the three processes of pre-forging, finish-forging and finish-rolling is distributed according to the percentage of the total deformation, wherein the deformation of the pre-forging process is 70% -80% of the total deformation, the deformation of the finish-forging process is 15% -20% of the total deformation, the deformation of the finish-rolling process is 5% -10% of the total deformation, the pre-forging temperature is controlled to be 1000 ℃ -1200 ℃, the finish-forging temperature is controlled to be 900 ℃ -1100 ℃, the finish-rolling temperature is controlled to be 880 ℃ -1080 ℃, and the average strain rate of each stage is controlled to be in the range of 0.1 s-1.0 s-1 in the pre-forging, finish-forging and finish-rolling processes.
5. The wheel forging and rolling composite forming process and the tissue regulating and controlling method based on deformation distribution according to claim 4, wherein the total deformation is distributed according to a volume invariance principle by combining characteristic dimensions of different deformation stages, and a specific distribution formula is as follows: And (3) pre-forging forming distribution: =(0.10~0.15)L, =(0.12~0.18)L, =(0.13~0.16)L, =(0.05~0.08)L, =(0.08~0.13)L, =(1.40~1.50)D; And (3) final forging forming distribution: =(0.08~0.11)L, =(0.16~0.19)L, =(0.07~0.08)L, =(0.06~0.8)L, =(0.09~0.10)L, =(0.09~0.11)L, =(1.42~1.52)D; finish rolling forming distribution: =(0.08~0.10)L, =(0.09~0.11)L, =(1.8~2.0)D; Wherein D is the original blank radius, L is the original blank height, L g1 is the pre-forged hub height, L gw1 is the pre-forged outer hub height, L gn1 is the pre-forged inner hub height, L f1 is the pre-forged web height, l ww1 is the height of the pre-forging outer rim, L wn1 is the height of the pre-forging inner rim, d f1 is the outer diameter of the pre-forging rim, L g2 is the height of the final-forging hub, L gw2 is the height of the finish-forging outer hub, L gn2 is the height of the finish-forging inner hub, L f2 is the height of the finish-forging web, L ww2 is the height of the finish-forging outer rim, L wn2 is the height of the finish-forging formed inner rim, d f2 is the outer diameter of the finish-forging formed rim, L g3 is the height of the finish-rolling formed hub, L gw3 is the height of the finish-rolling formed outer hub, L gn3 is the finish-rolled inner hub height, L f3 is the finish-rolled web height, L ww3 is the finish-rolled outer rim height, L wn3 is the finish-rolled inner rim height and rim outer diameter, and d f3 is the finish-rolled outer rim diameter.
6. The wheel forging and rolling composite forming process and the structure regulating and controlling method based on deformation distribution according to claim 5, wherein after the finish rolling forming, the wheel is subjected to slow cooling or online heat treatment.
7. The wheel forging and rolling composite forming process and the structure regulating and controlling method based on deformation distribution according to claim 6, 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.
8. The wheel forging and rolling composite forming process and tissue regulating and controlling method based on deformation distribution according to claim 7, 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, and the microstructure state variables comprise average grain size and recrystallization volume fraction.
9. The wheel forging and rolling composite forming process and tissue regulating and controlling method based on deformation distribution according to claim 8, wherein the forging-rolling forming macro-micro coupling model is realized by finite element simulation software Deformam 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.
10. The deformation distribution-based wheel forging and rolling composite forming process and the structure regulating and controlling method according to claim 9, 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, Taking 15 degrees for the large-angle grain boundary orientation difference; In the formula, Is poisson's ratio; In the formula, Is a constant; In the formula, 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

Wheel forging and rolling composite forming process and structure regulating and controlling method based on deformation distribution Technical Field The invention belongs to the technical field of locomotive wheel processing and manufacturing, and particularly relates to a wheel forging and rolling composite forming process and a tissue regulating and controlling method based on deformation distribution. Background Locomotive wheels are key components of a railway transportation system, and the quality of the locomotive wheels is directly related to the running safety, stability and service life of a train. With the development of railway equipment to high speed, heavy load and light weight, the performance requirements on wheels are increasingly severe, high strength, toughness and fatigue performance are required, and higher requirements on dimensional accuracy and weight control are also put on, so that a wheel with a complex structure with a deeper rim, thinner web or complex profile appears. In the prior art, although a 'forging-rolling combination' attempt is adopted, the prior art is generally only simple procedure connection, the inherent relation among deformation, a temperature field and microstructure evolution cannot be systematically considered from the whole forming link, and the prior art generally lacks active regulation capability on the microstructure evolution, and is mainly characterized in that firstly, a microstructure prediction method of the system is lacking, the influence of different deformation parameters on key tissue characteristics such as final grain size, recrystallization fraction and the like cannot be accurately predicted in a process design stage, secondly, a quantitative mapping relation between the process parameters and the microstructure cannot be established, so that the selection of key parameters such as deformation distribution, temperature control and the like still mainly depends on experience, theoretical guidance is lacking, and thirdly, an effective tissue regulation means is lacking, and the tissue refinement or homogenization of a specific part is difficult to be actively realized through the optimal design of the process parameters. In particular, the prior art fails to disclose and synergistically optimize the inherent coupling relationships between deflection distribution, temperature field evolution, and microstructure dynamic response (e.g., dynamic recrystallization, grain growth) from a systematic perspective throughout the thermomechanically shaped link. Due to the lack of a scientific tissue prediction and regulation method, technological parameters of each procedure are often designed independently, and global cooperative optimization based on tissue evolution prediction cannot be realized, so that the comprehensive performance of a final product is difficult to accurately regulate. For example, if the deformation amount or temperature control is improper in the early forging stage, the core structure is difficult to sufficiently refine, and the toughness is affected, and if the deformation amount distribution or finishing temperature is not reasonable in the later rolling stage, microscopic defects or unfavorable residual stress distribution may be induced in the root of the thin web or rim. Therefore, the development of the integrated method for the composite forming and the predictive control, which can integrate the tissue prediction and the active control function from the coupling point of macroscopic forming and microscopic evolution, systematically and cooperatively control the forming precision, reduce the load and realize the ideal uniform microstructure, has become an urgent technical requirement for meeting the manufacturing requirement of the locomotive wheels with the new generation of high-performance complex structures. Disclosure of Invention Aiming at the problem that the prior art lacks the capability of actively regulating and controlling the microstructure evolution, the invention provides a wheel forging and rolling composite forming process and a tissue regulating and controlling method based on deformation distribution. In order to achieve the above purpose, the present invention adopts the following technical scheme: the wheel forging and rolling composite forming process based on deformation distribution and the structure regulating and controlling method comprise a forging and rolling composite forming process and microstructure regulation and control, wherein: The forging and rolling composite forming process comprises the following steps: Pre-forging, namely pre-forging the blank heated to the forging temperature to drive the metal to deform axially for preliminarily forming the shape profile of the outer hub surface and the web of the wheel; Finish forging forming, namely, finish forging the pre-forged blank, and driving the metal to axially deform so as to form the shape contours of an outer wheel hub surface, an i