Optimization analysis of die mass and particle model in metal powder impact compaction
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摘要: 在模拟金属粉末冲击压制时，由于模型颗粒数与实际不同，仿真模型的准确度不高。本文引入模型冲模质量与实验冲模质量比值作为当量质量，研究了压制初始速度、横向与纵向颗粒数对当量质量的共同影响。采用ABAQUS软件建立了不同初始速度下的压制模型，利用1stOpt软件拟合出预估模型，通过ABAQUS仿真数据验证了预估模型，取得了当量质量与相对密度之间的关系，并且分别得到了横向与纵向两组模型的初始速度、颗粒数对冲模当量质量的影响关系。利用ABAQUS仿真数据得到的预估模型最终形式为：当冲模初始速度为20 m·s-1时，横向颗粒数为5、纵向颗粒数为6（H5Z6）的颗粒模型的当量质量为1.03，比经典9颗粒模型进行模拟更能接近实际的压制情形。Abstract: In the simulation of metal powder impact compaction, the simulation model is not accurate because of the particle number difference between the model and actuality. Therefore, the relative mass was introduced as the die mass ratio between the simulation and experiment, and the influences of initial pressing velocity and particle array in transverse and longitudinal direction on the relative mass were study in this paper. The ABAQUS software was used to establish the compaction model at different initial velocity. The prediction formula was fitted by 1stOpt software. Finally, the simulation model was used to verify the prediction formula, draw the relationship between the relative mass and relative density, and obtain the relationship between the initial velocity and particle array in transverse and longitudinal direction. In the result, the final formula is obtained by using ABAQUS simulation data. When the die velocity is 20 m·s-1, the relative mass in H5Z6 particle model (5 particles in transverse direction and 6 particles in longitudinal direction) is 1.03, which is closer to the actual pressing than that of the nine-particles model.
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图 1 粉末颗粒微观模型：（a）单颗粒细化网格；（b）横向模型；（c）纵向模型
Figure 1. Micro-deformation diagram of numerical simulation model: (a) grids; (b) transverse model; (c) longitudinal model
图 3 压制模拟结果：（a）m1 = 0.1m0；（b）m1 = m0
Figure 3. Simulation result of compaction: (a) m1 = 0.1m0; (b) m1 = m0
图 4 初始速度18 m·s-1横向、纵向模型相对密度与当量质量关系：（a）横向模型；（b）纵向模型
Figure 4. Relationship between relative density and relative mass at 18 m·s-1: (a) transverse model; (b) longitudinal model
图 5 初始速度26 m·s-1时横向模型、纵向模型相对密度与当量质量关系：（a）横向模型；（b）纵向模型
Figure 5. Relationship between relative density and relative mass at 26 m·s-1: (a) transverse model; (b) longitudinal model
图 12 预估模型计算值与试验值拟合结果
Figure 12. Fitting results of calculation value and experimental value in the prediction model
图 13 横向颗粒数为5，纵向颗粒数为6（H5Z6）的模型模拟结果
Figure 13. Simulation result of H5Z6 particle model as 5 particles in transverse direction and 6 particles in longitudinal direction
表 1 铝粉物理性能和相关参数
Table 1. Physical properties and relative parameters of aluminum powders
密度/ (kg·m-1) 熔化温度/ ℃ 泊松比 弹性模量/ GPa 屈服强度/ MPa 应变硬化模量/ MPa 应变硬化指数 应变速率敏感指数 温度软化系数 2770 604 0.33 71.7 337 343 0.41 0.009 1 
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表 2 水平因素正交表
Table 2. Orthogonal array of level and factor
水平 冲模初始速度（因素A）/ (m·s-1) 横向颗粒数（因素B） 纵向颗粒数（因素C） 水平1 18 3 3 水平2 20 4 4 水平3 22 5 5 水平4 24 6 6 水平5 26 7 7
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