数控弯管回弹的有限元数值预测与补偿研究
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摘要
薄壁弯管件以其优良的力学性能、多样的功用性和较高的性价比在航空航天等领域获得了广泛的应用。回弹是管材弯曲卸载后必然发生的现象，回弹现象的存在严重影响了弯管生产的精度和效率，从而也就成为重点研究对象之一。因此，本文采用有限元数值模拟对不锈钢和铝合金两种材料薄壁管件的弯曲回弹规律进行了详细的研究，主要的研究内容及成果如下：
(1) 研究了薄壁管件的弯曲成形机理，对该成形过程建立了符合实际的弹塑性有限元模拟模型。对管弯曲回弹有限元模型中的关键技术进行了研究，模拟中采用三维管弯曲几何模型，并采用八节点实体单元实现计算模型的离散化。对于弯曲过程中的接触问题采用了面一面接触模式，并采用库仑摩擦模型处理接触面间的摩擦问题。有限元模型的建立及关键技术的处理为弯管回弹规律的研究奠定了基础。
(2) 基于管弯曲回弹有限元模拟模型研究了弯曲工艺参数和材料参数对管弯曲回弹的影响规律。结果表明，弯管回弹角随弯管角度、相对弯曲半径及芯棒与管壁间隙的增大而增大；随材料硬化指数的增大而减小；随材料硬化系数的增大而增大。
(3) 基于已获得的弯管曲回弹规律，采用VB(Visual Basic)语言、SQL(Structure Query Language)语言及微软Access数据库软件设计并开发了通过数控过弯实现弯管回弹补偿的系统。从而为管材弯曲回弹角的补偿提供了一条可行的途径。
The thin-wall tubes are widely used in lots of fields because of their excellent properties, various functions and hige feature-price ratio, such as in aviation and astronavigation fields etc. The springback which happens consequentially after unloading is a flaw which acutely reduced the efficient production of the tubes, and at present, much research work have been done about finding the appropriate solution to the springback. This paper conducted the detailed research to obtain the rules existing in the bending springback phenomenon of the stainless steel tube and the Al-alloy tube, based on the elasto-plasticity FEM. The main research content and achievements are as follows:
(1) Based on the research of the forming mechanism of tube bending, the elastic-plastic FEM simulation model which is very important to the research of the springback rules of bending tube has been established, the essential technical questions to carry out the simulation was treated as well. The deforming body was dispersed by eight-node solid element, and surface-to-surface contact element was used for creating the contact pair, besides, the Coulomb friction model was used to solve the friction questions between contact faces.
(2) Based on the tube bending FEM simulation model, the tube bending springback rule under the different craft parameters and the material parameters was studied. The results indicated that the springback quantity of bent tube grows with the increasing of the elbow piece angle, the relative bending radius and the gap between the core craft and the tube wall, falls down with the increment of material hardening index value, and increases with the increment of the material hardening coefficient value.
(3) Based on the obtained bent-tube's springback rules , the VB language, the SQL language and Microsoft Access database software, an over-bending compensate system of the NC tube bending springback was designed and developed. This system can provide a feasible method to compensate the springback angle of tube bending process.
(1) 研究了薄壁管件的弯曲成形机理，对该成形过程建立了符合实际的弹塑性有限元模拟模型。对管弯曲回弹有限元模型中的关键技术进行了研究，模拟中采用三维管弯曲几何模型，并采用八节点实体单元实现计算模型的离散化。对于弯曲过程中的接触问题采用了面一面接触模式，并采用库仑摩擦模型处理接触面间的摩擦问题。有限元模型的建立及关键技术的处理为弯管回弹规律的研究奠定了基础。
(2) 基于管弯曲回弹有限元模拟模型研究了弯曲工艺参数和材料参数对管弯曲回弹的影响规律。结果表明，弯管回弹角随弯管角度、相对弯曲半径及芯棒与管壁间隙的增大而增大；随材料硬化指数的增大而减小；随材料硬化系数的增大而增大。
(3) 基于已获得的弯管曲回弹规律，采用VB(Visual Basic)语言、SQL(Structure Query Language)语言及微软Access数据库软件设计并开发了通过数控过弯实现弯管回弹补偿的系统。从而为管材弯曲回弹角的补偿提供了一条可行的途径。
The thin-wall tubes are widely used in lots of fields because of their excellent properties, various functions and hige feature-price ratio, such as in aviation and astronavigation fields etc. The springback which happens consequentially after unloading is a flaw which acutely reduced the efficient production of the tubes, and at present, much research work have been done about finding the appropriate solution to the springback. This paper conducted the detailed research to obtain the rules existing in the bending springback phenomenon of the stainless steel tube and the Al-alloy tube, based on the elasto-plasticity FEM. The main research content and achievements are as follows:
(1) Based on the research of the forming mechanism of tube bending, the elastic-plastic FEM simulation model which is very important to the research of the springback rules of bending tube has been established, the essential technical questions to carry out the simulation was treated as well. The deforming body was dispersed by eight-node solid element, and surface-to-surface contact element was used for creating the contact pair, besides, the Coulomb friction model was used to solve the friction questions between contact faces.
(2) Based on the tube bending FEM simulation model, the tube bending springback rule under the different craft parameters and the material parameters was studied. The results indicated that the springback quantity of bent tube grows with the increasing of the elbow piece angle, the relative bending radius and the gap between the core craft and the tube wall, falls down with the increment of material hardening index value, and increases with the increment of the material hardening coefficient value.
(3) Based on the obtained bent-tube's springback rules , the VB language, the SQL language and Microsoft Access database software, an over-bending compensate system of the NC tube bending springback was designed and developed. This system can provide a feasible method to compensate the springback angle of tube bending process.
引文
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2．杨合，林艳，孙志超．面向21世纪的先进塑性加工技术与管成形研究发展中国科学协会第二届学术年会文集．2000：745～746
3．张士宏．塑性加工技术的科学化与中国塑性加工技术的发展．科学前沿与学术评论．23(5)：5～11
4．张士宏．塑性加工技术的最新进展．中国机械工程．1994，5(2)：70～71
5．钟毅．金属塑性加工技术的发展．昆明理工大学学报．1998，23(6)：32～35
6．杨合，孙志超，林艳，李明奇．管成形技术发展基础问题研究．塑性工程学报．2001，8(2)：71-7～3
7．李晓星．板材成形模拟的研究和应用．金属成形工艺．2003，21(2)：6～9
8．高忠江．大直径钢管的冷压弯曲成形．锻压技术．1991，42(83)：55～58
9．金国名．芯棒的选取和使用．模具技术．1998，(4)：62～65
10．高越风．薄壁钢管弯曲过程论证及杆芯的优化设计．铁道技术监督．2001，(1)：27～28
11．陈志浩，陈训广．薄壁无缝钢管的冷弯及精度控制．机械制造．1991，(8)：15～17
12．周遐余．薄壁管冷弯成型中芯棒的结构分析及设计．工艺与工艺装备．2003，(5)：53～54
13．王晓林．金属板弹塑性非圆弧弯曲回弹的计算．塑性工程学报．1996，3(4)：27～33
14．金国名，郭雅丽．常见弯管缺陷与预防措施．模具技术．1999，(4)：64～67
15．肖景荣，姜奎华．冲压工艺学．机械工业出版社，1992
16．汪大年．金属塑性成形原理．机械工业出版社，1995
17．翟福宝，林新波，张质良，夏萼辉．有限元模拟在金属塑性成形中的应用．锻压机械．2000，(3)：46～48
18．赵幼平，许可芳．真空助力器壳体结构优化设计中的应用．设计与计算．1997，(1)：12～13
19．丁建平，俞淇．有限元法在轮胎结构设计中的分析与应用．橡胶工业．1995，45(5)：304～315
20．李秀英，黄力明，杨耀文，孙力行，刘正兴．用有限元法计算异步电机机座的强度刚度．中小型电机．1996，23(5)：20～22
21．吴明，陆钟武，蔡九菊．有限元法计算重油管线工艺参数．油气田地面工程．1995，14(6)：16～18
22．闵次凡，王建华．用有限元法计算电机磁场的网格自动剖分问题．计算机与现代化．1996，(1)：33～36
23. Gang Liu, Shijian YUAN, Mingxue ZHANG. Numerical Analysis on Rotary Forging Mechanism of a Flange. J.Mater. Sci.Technol. 2001, 17(1):129～130
24．王勖成，邵敏．有限单元法基本原理和数值方法．清华大学出版社．1995(2)
25. R.M. McMeeking, J.R. Rice. Finite Element Formulations for Problems of Large Elastic-Plastic Deformation. International Journal of Solids and Structures. 1995, (121):601～616
26．吴华，蒋浩民，汪承璞．数值模拟在汽车板成形中的应用．宝钢技术．2002，(1)：48～51
27．王圣平．汽车覆盖件成形过程数值模拟研究．塑性工程学报．1996，3(2)：41～48
28．罗亚军，杨曦，何丹农，张永清．板料成形中的有限元数值模拟技术．金属成形工艺．2000，18(6)：1～3
29．李尧臣．金属板料冲压成形的有限元法模拟．力学学报．1995 27(3)：351～364
30．张海明，董湘怀，李尚健，李志刚．板材成形模拟系统的开发应用．模具工业．2001，248(10)：3～6
31．于恩林，赖明道．薄板大位移弹塑性有限元分析．焊管．1994，17(5)：1～4
32．邵鹏飞，王秀喜．金属板料冲压成形过程的数值模拟．机械设计与研究．2000，(2)：22～24
33. K.B. Nielsen, M.R. Jensen, J.Danckert. Optimization of sheet metal forming processes using finite element simulations. Acta Metallurgica Sinica (English Letters). 2000, 4(13):531～539
34. S.C. Tang. Quasi-static analysis of sheet metal forming processes-a design evaluation tool. Journal of Materials Processing Technology. 1994, (45):261～266
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