A process parameter correction method based on mold wear, electronic equipment and medium

Abstract

The present invention relates to a process parameter correction method based on die wear, an electronic device and a medium. The method comprises: providing a set of dies and corresponding blanks, using a designated device to set preliminary test parameters; performing a test according to the test parameters, and recording the test wear depth obtained; using finite element analysis software to create a forging model including the die and the blank; setting the analysis step, contact parameters and mesh division in the forging model; in the finite element analysis software, programming the wear depth calculation formula into a subroutine, performing a preliminary setting of the wear constant and performing a simulation; comparing the wear depth of the simulation result with the test wear depth, repeatedly adjusting the wear constant until the simulation result matches the test result, and determining the final correction wear constant. The present invention determines the correction wear parameters by combining finite element analysis software and test data, and the die wear condition can be well predicted by the correct wear parameters.

Description

Technical Field

[0001] The invention belongs to the fields of mechanical engineering and computer science, and specifically relates to a process parameter correction method based on mold wear, electronic equipment and medium. Background Art

[0002] Mold wear refers to the damage or loss of part or all of the metal or non-metallic material on the surface during repeated pressing, extrusion, stretching, bending, etc., which shortens the service life of the mold. Mold wear is the most common failure form in metal plastic processing. It not only affects the dimensional accuracy of the product, but also directly affects the production efficiency and product quality. Therefore, reducing mold wear is of great significance to ensure product quality and improve production efficiency.

[0003] The determination of the wear coefficient is of great significance to the study of the wear of the same mold. In traditional simulations or actual calculations, the determination of the wear coefficient is often obtained through Archard theory calculations. However, the application of the Archard model is usually based on some simplified assumptions, such as uniform wear and constant load. Archard theory only considers the wear rate, wear volume, load, and wear distance, and ignores many important factors. This model may be effective for some simple wear phenomena, but in actual applications, due to the complexity of wear behavior, wear is affected by many factors such as the material of the friction pair and surface damage. The existing Archard theory does not include it, so it is necessary to consider combining other factors for correction.

[0004] Traditional Archard model:

[0005]

[0006] Where: K c is the wear constant of Archard's model; V c is the wear volume (mm 3 );L c is the relative slip distance (mm); H c is the elastic modulus (mm); P c It represents the total normal load (N) applied to the wearing surface. Summary of the invention

[0007] The present invention provides a process parameter correction method based on mold wear, an electronic device and a medium, the purpose of which is to solve the problem of insufficient mold wear prediction and compensation methods in the prior art.

[0008] To achieve the above object, the first aspect of the present invention provides a method for correcting process parameters based on mold wear, comprising the following steps:

[0009] Provide a set of dies and corresponding blanks, and use the specified equipment to set preliminary test parameters;

[0010] Perform a test according to the test parameters and record the test wear depth obtained;

[0011] Using finite element analysis software to create a forging model including the die and the blank;

[0012] Setting the analysis steps, contact parameters between the die and the blank, and meshing of the contact area between the die and the blank in the forging model;

[0013] In the finite element analysis software, the wear depth calculation formula is compiled into a subroutine, the wear constant is preliminarily set, and the simulation is performed according to the test parameters in the test to obtain the wear depth of the simulation result;

[0014] The wear depth of the simulation results is compared with the test wear depth. If the wear depth of the simulation results matches the test wear depth, the wear constant set in the simulation result is determined as the final corrected wear constant. Otherwise, the wear constant in the wear depth calculation formula is repeatedly adjusted until the wear depth of the simulation results matches the test wear depth, and the final corrected wear constant is determined.

[0015] Furthermore, the wear depth calculation formula is as follows:

[0016]

[0017] Wherein, h is the wear depth; V is the wear volume; A is the wear area; k is the wear constant; E is the mold elastic modulus; p is the average contact pressure; H is the mold hardness; t is the contact time; v is the mold forward running speed; dt is the time step.

[0018] Furthermore, the analysis steps are set to include:

[0019] Open the simulation model in the finite element analysis software and enter the settings module;

[0020] Create an initial contact analysis step and define the initial contact state;

[0021] Create a load analysis step, apply loads, set the time period and increment steps;

[0022] Create friction and wear analysis steps, define friction behavior, set friction coefficient, and set the corresponding time period and increment steps;

[0023] Create an unloading analysis step, unload the load, set the time period and increment steps, and return the model to the unloaded state;

[0024] Save the analysis step settings and complete the definition of the simulation model process.

[0025] Furthermore, setting the contact parameters between the die and the blank includes: setting the slip limit between the contact surfaces in the finite element analysis software, specifying the sliding friction coefficient of the contact surfaces, and setting the pressure distribution mode of the contact surfaces.

[0026] Furthermore, meshing the contact area between the mold and the blank includes: refining the area where wear occurs, wherein the mesh size of the wear contact part is set to 10 μm, and the mesh size of other parts is set to 50 μm.

[0027] Furthermore, before performing the wear simulation, the initial contact conditions between the die and the blank, including the contact area and the expected initial wear position, are determined through one or more preliminary experiments.

[0028] Furthermore, before the wear depth calculation formula is incorporated into the subroutine, a preliminary physical test is conducted to obtain experimental wear data for the preliminary setting of the wear constant.

[0029] Furthermore, the relative motion parameters between the die and the blank are set in the simulation environment, including the forward running speed of the die, the friction coefficient, and the time period of the motion.

[0030] To achieve the above object, the second aspect of the present invention provides an electronic device, comprising: at least one memory and at least one processor;

[0031] The at least one memory is used to store a readable program;

[0032] The at least one processor is used to call the readable program to execute the method.

[0033] To achieve the above objective, the third aspect of the present invention provides a computer-readable medium, on which computer instructions are stored. When the computer instructions are executed by a processor, the processor executes the method.

[0034] The beneficial effects of the present invention are:

[0035] The present invention proposes an innovative method for correcting mold wear process parameters, and applies it to electronic equipment and media, significantly improving the deficiencies of existing technologies in predicting and compensating for mold wear. Existing technologies usually rely on a simplified Archard model, which is effective in dealing with simple wear problems, but ignores the complexity of wear behavior, such as the influence of friction pair materials, surface damage and other factors. The present invention combines experiments with simulations, sets analysis steps in a simulation environment, adjusts mold and blank contact parameters, and performs fine gridding on the contact area, so that the simulation is closer to actual working conditions. In addition, by incorporating the wear depth calculation formula into a subroutine and comparing and adjusting it with actual test data, the present invention can iteratively correct the wear constant and ultimately obtain a simulation output consistent with the test results, thereby achieving accurate wear prediction and real-time correction of process parameters. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments.

[0037] Figure 1 It is a flow chart of a method for correcting process parameters based on mold wear disclosed in an embodiment of the present invention.

[0038] Figure 2 This is an example diagram of wear calculation of two micro-protrusions disclosed in an embodiment of the present invention.

[0039] Figure 3 It is a simplified model diagram for establishing ball block friction and wear disclosed in an embodiment of the present invention.

[0040] Figure 4 It is a grid division diagram disclosed in an embodiment of the present invention.

[0041] Figure 5 It is a comparison diagram of the uncorrected simulation model and the experimental wear curve data disclosed in the embodiment of the present invention.

[0042] Figure 6 This is a wear depth diagram under simulation at 3N disclosed in an embodiment of the present invention.

[0043] Figure 7 This is a wear depth diagram under simulation at 10N disclosed in an embodiment of the present invention.

[0044] Figure 8 This is a wear depth diagram under simulation at 20N disclosed in an embodiment of the present invention.

[0045] Fig. 9 It is a comparison diagram of the corrected simulation model and the experimental wear curve data disclosed in the embodiment of the present invention. DETAILED DESCRIPTION

[0046] like Figure 1 As shown, the present invention provides a method for correcting process parameters based on mold wear, the method comprising the following steps:

[0047] Step S100, providing a set of molds and corresponding blanks, and using designated equipment to set preliminary test parameters;

[0048] Step S200, performing a test according to the test parameters, and recording the obtained test wear depth;

[0049] Step S300, using finite element analysis software to create a forging model including the die and the blank;

[0050] Step S400, setting the analysis step, the contact parameters between the die and the blank, and the meshing of the contact area between the die and the blank in the forging model;

[0051] Step S400 involves setting key simulation parameters in the finite element simulation environment, including defining analysis steps (such as loading, wear process and unloading, etc.), adjusting the contact parameters between the die and the blank (such as contact type, friction coefficient, etc.), and fine meshing the contact area between the die and the blank. This step ensures that the simulation more accurately reflects the actual operating conditions. By refining the mesh, the resolution of the contact area can be improved, thereby obtaining more accurate stress, strain and wear data.

[0052] Step S500, in the finite element analysis software, the wear depth calculation formula is compiled into a subroutine, the wear constant is preliminarily set, and simulation is performed according to the test parameters in the test to obtain the wear depth of the simulation result;

[0053] In this step, the software calculates the wear volume in each analysis step through a subroutine and calculates the wear depth based on the loading conditions and material properties. This requires setting the wear constant used in the simulation. The initial setting of the wear constant is based on theory or previous experimental data. For example, the test parameters and wear parameters in the test can be input into the calculation formula of the traditional Archard model. The wear constant k is calculated using this calculation formula. This wear constant is used as a preliminary wear constant and substituted into the formula. The wear constant is continuously adjusted and corrected in subsequent simulations. After the simulation, the software simulates the wear of the material in the actual working environment according to the set parameters and contact conditions, providing preliminary wear assessment results for the next step of correction and optimization.

[0054] Step S600, compare the wear depth of the simulation result with the test wear depth. If the wear depth of the simulation result matches the test wear depth, the wear constant set in the simulation result is determined as the final corrected wear constant. Otherwise, the wear constant in the wear depth calculation formula is repeatedly adjusted until the wear depth of the simulation result matches the test wear depth, and the final corrected wear constant is determined.

[0055] The simulation results generated by the finite element software are compared with the actual experimental data in order to verify and correct the wear constants used in the simulation. In this step, the wear depth parameters obtained by the simulation are compared in detail with the test results. Based on this comparison, the wear constants are repeatedly adjusted and optimized until the simulation results match the test results.

[0056] In this embodiment, the calculation formula of the wear depth is obtained as follows: Figure 2 As shown, it is assumed that the two worn parts are composed of n micro-convex bodies with a radius of r;

[0057] The total contact area is:

[0058] (1)

[0059] The total wear volume is:

[0060] (2)

[0061] And because the loads at all contact points are:

[0062] (3)

[0063] In the formula is the yield strength; Substituting formula (3) into (2), we can get:

[0064]

[0065] And because of the convex radius in Hertz contact theory:

[0066]

[0067] Let R = 1 / 2r, so

[0068]

[0069] Where E is the elastic modulus of the mold; therefore:

[0070]

[0071] Therefore the wear depth is:

[0072]

[0073] Since the specific mold wear is related to the contact time t and the mold forward running speed v, this model can be optimized as follows:

[0074]

[0075] Wherein, h is the wear depth; V is the wear volume; A is the wear area; k is the wear constant; E is the mold elastic modulus; p is the average contact pressure; H is the mold hardness; t is the contact time; v is the mold forward running speed; dt is the time step.

[0076] In traditional solutions, the wear condition of the mold can only be known through actual measurement or theoretical calculation, and the error between the result of theoretical calculation and the actual wear condition is large.

[0077] Specific test: The upper and lower mold materials are Si3N4, and the blank is NiAl alloy. The specific test parameters and results are as follows:

[0078] Test parameters and results:

[0079]

[0080] Substituting the material parameters in the table into the traditional Archard model calculation formula and the model calculation formula of this embodiment, the wear constant K of the traditional uncorrected Archard model can be calculated. c 1.11×10 -6 The wear constant k of the model in this embodiment is 2.3×10 -6 .

[0081] A specific simulation scheme is provided below:

[0082] Model establishment: The computer-aided design software SolidWorks was used to construct a three-dimensional model including the upper and lower molds and the blank. The upper and lower molds were made of silicon nitrogen ceramic (Si3N4) material, and the blank was made of nickel aluminum alloy (NiAl). Figure 3 .

[0083] Material parameter input: Enter the following material property parameters in the Abaqus finite element simulation software: Si3N4 mold: Young's modulus is 320Gpa, Poisson's ratio is 0.28, and density is 3.3e -9 (t / mm³), Vickers hardness is 1600HV. NiAl alloy billet: Young's modulus is 250Gpa, Poisson's ratio is 0.22, density is 7.3e -9 (t / mm³), Vickers hardness is 445HV.

[0084] Assembly: During the assembly phase, SolidWorks software is used to accurately combine the upper and lower molds and the blanks according to the design requirements to ensure their correct alignment in spatial position and direction. This process includes adjusting the blank to adapt to the shape and size inside the mold, and setting appropriate contact interfaces and gaps to simulate the contact conditions in actual processing. The accuracy of the assembly directly affects the actual performance of the simulation and the reliability of the output results. Therefore, it is necessary to ensure that the assembly of the mold and the blank in the virtual environment simulates the physical relationship in the actual working environment, including the possible slight displacement or contact pressure between the mold and the blank. Such an assembly ensures that the process of load transfer, stress distribution and wear generation can be accurately simulated in the subsequent simulation analysis.

[0085] Simulation step definition: The entire simulation process is subdivided into four main steps to simulate actual operating conditions: First is "Initial", in which the initial contact state of the die and the blank is set to ensure that the two are correctly aligned before any external force is applied. Next is the "Load" step, at this time, the predetermined loading force is gradually applied to the die to simulate the material response during the pressure process. Next is the "Wear" step, which simulates the friction and wear between the die and the blank during the actual processing process, and examines the amount and distribution of wear caused by friction. Finally, the "Zero" step simulates the unloading process and observes the state of the material after unloading to evaluate permanent deformation or damage. Each step accurately sets the time interval and specific loading conditions, and optimizes the calculation process and ensures the convergence of the numerical solution by adjusting the incremental steps, thereby ensuring the accurate execution of the simulation and the effectiveness of data collection.

[0086] Contact interface setting: Set the contact interface between the mold and the blank, using the surface-to-surface contact mode. Set the friction coefficient of the tangential behavior to 0.3, use the limited slip mode, and the fixed value of the sliding interface slip is 0.2.

[0087] Setting of boundary conditions: Set the vertical movement speed of the hydraulic press to 5 mm / s.

[0088] Meshing and Optimization: The model was meshed using Hypermesh software, for contact areas where friction and wear are expected, such as the contact surface between the die and the blank. In these critical areas, a finer mesh size (10 μm) was used, and the total number of meshes for the Si3N4 spheres in this model was approximately 23,968. Similarly, the mesh of the key research area of ​​the NiAl alloy disk at the lower end was refined, and the mesh size of the wear contact part was refined to 10 μm. For other less critical areas, a coarser mesh (50 μm) was used to optimize computational efficiency and reduce processing time. The total number of meshes for the NiAl alloy disk is approximately 107,016, see Figure 4 .

[0089] Application of adaptive mesh technology (ALE technology): In order to adapt to the material deformation and damage during the wear process, the mesh in the contact area is divided into partitions of each unit using ALE adaptive mesh technology, realizing the control of deformable partitions. All meshes are assigned the unit type as C3D8R, and hourglass control enhancement is selected in the control to prevent excessive deformation of the model.

[0090] Wear model integration and simulation operation: Integrate the modified Archard wear model (i.e., wear depth calculation formula) into the Umeshmotion subroutine in Abaqus. The subroutine automatically calculates the wear amount based on parameters such as contact pressure, sliding distance, and material hardness calculated in real time.

[0091] Simulation monitoring and data analysis: Start the simulation analysis, monitor the execution of each analysis step, collect detailed data on mold wear, and compare the simulation results with experimental measurement data to verify the accuracy and reliability of the model.

[0092] Result optimization: According to the comparison results between simulation and experiment, the wear constant K in the subroutine was repeatedly adjusted to make the wear depth and width curves of the test as consistent as possible during simulation. The corrected wear coefficient was 2.3×10 -6 By comparing the wear depth obtained by simulation with the test, the wear morphology obtained by finite element simulation and the test wear morphology are gradually approached, and the actual wear coefficient of the mold is finally determined.

[0093] Result analysis: According to the traditional uncorrected Archard model, the calculated wear constant of the Archard model is about 1.11×10 -6 Substituting this data into the simulation model, the calculated wear curve is as follows: Figure 5 The study shows that there is a big difference between the experimental data and the simulation data under this model. The reason is that the classical numerical simulation method of the Archard model cannot be used to accurately predict the wear state of the material.

[0094] like Figure 6-Figure 9 After correcting the wear constant, the comparison between the model and the test results shows that under all loads, the wear depth shows a shallow to deep wear from the outside to the inside. At 3N, the deepest wear under simulation is about 3.77μm, and the test wear depth is 3.8μm; at 10N, the deepest wear under simulation is about 5.6μm, and the test wear depth is 5.8μm; at 20N, the deepest wear under simulation is about 9.59μm, and the test wear depth is 9.6μm. The comparison of simulation and test data shows that the simulation and test are in good agreement.

[0095] Comparison of the simulation calculation results after wear constant correction with the friction and wear test curve data shows that under three different loads, the wear depth and wear width curves obtained by simulation are closer to the test values, and the wear profile restoration is more accurate.

[0096] Furthermore, this embodiment also provides an electronic device, including: at least one memory and at least one processor;

[0097] The at least one memory is used to store a readable program;

[0098] The at least one processor is configured to call the readable program to execute the method.

[0099] This embodiment further provides a computer-readable storage medium, on which computer instructions are stored. When the computer instructions are executed by a processor, the processor executes the method.

[0100] A person skilled in the art should understand that the discussion of any of the above embodiments is merely illustrative and is not intended to imply that the scope of protection of the present application is limited to these examples. In line with the concept of the present application, the technical features in the above embodiments or different embodiments may be combined, the steps may be implemented in any order, and there are many other variations of different aspects of one or more embodiments of the present application as described above, which are not provided in detail for the sake of simplicity.

[0101] In addition, the above-mentioned figures are only schematic illustrations of the processes included in the method according to the embodiment of the present disclosure, and are not intended to be limiting. It is easy to understand that the processes shown in the above-mentioned figures do not indicate or limit the time sequence of these processes. In addition, it is also easy to understand that these processes can be performed synchronously or asynchronously, for example, in multiple modules.

[0102] Those skilled in the art will readily appreciate other embodiments of the present disclosure after considering the specification and practicing the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the present disclosure that follow the general principles of the present disclosure and include common knowledge or customary technical means in the art that are not disclosed in the present disclosure. The specification and examples are to be considered as exemplary only, and the true scope and spirit of the present disclosure are indicated by the claims.

[0103] It should be understood that the present disclosure is not limited to the exact structures that have been described above and shown in the drawings, and that various modifications and changes may be made without departing from the scope thereof. The scope of the present disclosure is limited only by the appended claims.

Claims

1. A process parameter correction method based on mold wear, characterized in that: The steps include: Provide a set of dies and corresponding blanks, and use the specified equipment to set preliminary test parameters; Perform a test according to the test parameters and record the test wear depth obtained; Using finite element analysis software to create a forging model including the die and the blank; Setting the analysis steps, contact parameters between the die and the blank, and meshing of the contact area between the die and the blank in the forging model; In the finite element analysis software, the wear depth calculation formula is compiled into a subroutine, the wear constant is preliminarily set, and the simulation is performed according to the test parameters in the test to obtain the wear depth of the simulation result; The wear depth of the simulation results is compared with the test wear depth. If the wear depth of the simulation results matches the test wear depth, the wear constant set in the simulation result is determined as the final corrected wear constant. Otherwise, the wear constant in the wear depth calculation formula is repeatedly adjusted until the wear depth of the simulation results matches the test wear depth, and the final corrected wear constant is determined.

2. The process parameter correction method based on mold wear according to claim 1, characterized in that: The wear depth calculation formula is as follows: Wherein, h is the wear depth; V is the wear volume; A is the wear area; k is the wear constant; E is the mold elastic modulus; p is the average contact pressure; H is the mold hardness; t is the contact time; v is the mold forward running speed; dt is the time step.

3. The process parameter correction method based on mold wear according to claim 1, characterized in that: Setting the analysis steps includes: Open the simulation model in the finite element analysis software and enter the settings module; Create an initial contact analysis step and define the initial contact state; Create a load analysis step, apply loads, set the time period and increment steps; Create friction and wear analysis steps, define friction behavior, set friction coefficient, and set the corresponding time period and increment steps; Create an unloading analysis step, unload the load, set the time period and increment steps, and return the model to the unloaded state; Save the analysis step settings and complete the definition of the simulation model process.

4. The process parameter correction method based on mold wear according to claim 3, characterized in that: Setting contact parameters between the die and the blank includes: setting a slip limit between contact surfaces in finite element analysis software, specifying a sliding friction coefficient of the contact surface, and setting a pressure distribution pattern of the contact surface.

5. The process parameter correction method based on mold wear according to claim 1, characterized in that: The mesh division of the contact area between the die and the blank includes: refining the area where wear occurs, wherein the mesh size of the wear contact part is set to 10 μm, and the mesh size of other parts is set to 50 μm.

6. The process parameter correction method based on mold wear according to claim 1, characterized in that: Before performing wear simulation, the initial contact conditions between the die and the blank, including the contact area and the expected initial wear position, are determined through one or more preliminary experiments.

7. The process parameter correction method based on mold wear according to claim 1, characterized in that: Before programming the wear depth calculation formula into the subroutine, a preliminary physical test was conducted to obtain experimental wear data for the preliminary setting of the wear constants.

8. The process parameter correction method based on mold wear according to claim 1, characterized in that: The relative motion parameters between the die and the blank are set in the simulation environment, including the forward running speed of the die, the friction coefficient, and the time period of the motion.

9. An electronic device, characterized in that: include: at least one memory and at least one processor; The at least one memory is used to store a readable program; The at least one processor is used to call the readable program to execute the method according to any one of claims 1 to 8.

10. A computer-readable medium, characterized in that The computer-readable medium stores computer instructions, which, when executed by a processor, cause the processor to execute the method according to any one of claims 1 to 8.

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