Parameters Design System For Electrical Upsetting Process Of Large Nickel-based Superalloy Valve And Its Application

The electric upsetting process of large nickel-based valve is an electro-thermal coupling process involving multi-fields.These process parameters affect each other and the free combination of the various parameters will lead to different results,which greatly increases the difficulty of processing data management and processing parameter design.In order to manage the historical upset process cases systematically,this paper developed an electric upsetting process data management system,which has the function of inquiring the historical cases and comparing the loading paths and results of different upset cases.Furthermore,in order to solve the problem that the upsetting process parameters are difficult to be designed,an automatic design method for the electric upsetting process parameters was proposed.The method consists of three steps.Firstly,the process parameters of initial state of electric upsetting are designed.It can be realized with the aid of BP neural network.The fifteen historical electric upsetting cases were used as the training data for the neural network.The second step is the design of the electric upsetting continuous loading processing parameters,this part is implemented by using the method of case-based reasoning,a number of different specifications of the valve were taken as representatives for a large number of simulations to explore the loading patterns under valves with various diameters.Then,the different simulation results and corresponding loading pattern of different valves were put into a database.Through the search of diameter and load model of new valve to obtain the corresponding displacement of upsetting anvil,the increase and decrease gradient of current and force,the peak position of current and force.The design of process parameters for continuous loading of electric upset can be preliminarily completed by combining with the initial state process parameters with the loading patterns.In the third step,the electronic upsetting process parameters were fine-tuned by inserting a self-feedback upsetting force adjustment sub-program into the finite element software MSC.marc.Next,the above automatic design process of electric upsetting processing parameters was implanted into a whole system,and then an automatic design system of electric upsetting parameters was been developed.Finally,the effectiveness of the system was evaluated by taking the design of the electric upsetting process of a 55 mm diameter valve as an example.