Measurement of friction factor in plastic forming of Zr-4 alloy based on ring compression and extrusion–simulation
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摘要: 采用圓環壓縮法和擠壓–模擬法測定Zr-4合金有潤滑條件下的摩擦因子，討論了2種方法所測定摩擦因子存在差異的原因。研究結果表明，在模具（砧面）粗糙度Ra = 0.6 μm、實驗溫度700～800 ℃的條件下，采用圓環壓縮法獲得的Zr-4合金與模具的摩擦因子為0.18～0.27，摩擦因子隨實驗溫度的升高而增大。擠壓溫度為750 ℃時，采用擠壓–模擬法獲得的熱擠壓平均摩擦因子為0.35。測試結果存在較大差異的原因，是由于擠壓過程潤滑劑的剪切速率較圓環壓縮實驗大得多，且擠壓過程中潤滑劑所受壓應力約為圓環壓縮實驗中的兩倍，從而導致潤滑劑黏度的增大，表現為摩擦因子較高。圓環壓縮法獲得的摩擦因子更適合于Zr-4合金的鍛造等熱加工工況。Abstract: Nuclear-grade zirconium alloys are characterized by large deformation resistance, poor fluidity, strong viscosity, and narrow forming temperature range. They are widely used in the nuclear industry and are a good choice for structural components and fuel cladding materials for nuclear power reactors. Reasonable process parameters and tooling design are very important for the production of zirconium alloy products with excellent performance. Simulation is an important technical means in plastic forming process and tool structure optimization. A prerequisite for accurate simulation is to determine precise boundary conditions, such as friction factors in plastic forming process. In this study, the friction factors under the lubrication condition of Zr-4 alloy were determined by ring compression and extrusion simulation method. The reasons for the difference in friction factors measured by the two methods were discussed. The results show that when the roughness of the die (anvil) is Ra = 0.6 μm and the experimental temperature is 700?800 ℃, the friction factor between the Zr-4 alloy and the die obtained by the ring compression is 0.18?0.27, and the friction factor increases with increasing in the experimental temperature. When the extrusion temperature is 750 ℃, the average friction factor of hot-extrusion obtained by extrusion simulation is 0.35. The reason for the large difference in the test results is that the shear rate of the lubricant in the extrusion process is much larger than that of the ring compression experiment, and the compressive stress of the lubricant in the extrusion process is about twice that in the ring compression experiment, which leads to an increase in the lubricant viscosity so that the friction factor is higher. The friction factor obtained by the ring compression method is more suitable for hot working conditions such as the forging of Zr-4 alloys.
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Key words:
- Zr-4 alloy /
- glass lubricants /
- ring compression /
- extrusion simulation /
- friction factor
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圖 3 不同摩擦力下圓環內徑變化. （a） 摩擦力較大; （b） 摩擦力較小
Figure 3. Changes in ring inner diameter under different friction degrees: (a) large friction; (b) small friction
圖 4 不同壓縮速度下圓環壓縮載荷–位移曲線. （a） 4 mm·min?1; （b） 10 mm·min?1
Figure 4. Ring compression load-displacement curve at different compressing velocities: (a) 4 mm·min?1; (b) 10 mm·min?1
圖 9 棒材擠壓 （a）與圓環壓縮（b）時表面流動示意圖
Figure 9. Diagram of surface flow during rod extrusion (a) and ring compression (b)
圖 10 棒材與圓環表面各點與模具的相對運動速度
Figure 10. Relative motion velocity of bar and ring surface with die
圖 11 圓環壓縮與棒材擠壓時坯料表面壓應力
Figure 11. Compressive stress on ingot surface during ring compression and bar extrusion
表 1 圓環壓縮實驗結果
Table 1. Results of ring compression experiment
試樣 潤滑 壓縮速度/（mm·min?1） 實驗溫度/℃ 壓縮量/% 內徑變化/% 摩擦因子，mt 1 無 10 750 34 ?26.8 1 2 有 10 700 34.9 0.27 0.19±0.01 3 有 10 750 34.6 ?1.13 0.22±0.02 4 有 10 800 34.8 ?3.9 0.27±0.01 7 有 4 700 29.8 1.13 0.18±0.01 8 有 4 750 29.8 ?1.4 0.21±0.01 9 有 4 800 30.4 ?3.1 0.27±0.02 
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