变截面薄板的冲压成形性能研究
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摘要
本文对变截面板(包括拼焊板和连续变截面板)这一新形式的板材的冲压成形性能进行了系统的研究。
首先,对材质为DC06和DC03的母材及变截面板进行了拉伸试验、杯突试验、拉深试验以及断口扫描试验等基础性研究,应用数值模拟对等厚板及拼焊板成形过程进行了分析,以掌握拼焊板在不同成形条件下的变形规律。
①拉伸试验表明:拼焊板焊缝角度小于一定范围内时,失效发生在焊缝上;随着厚度差增加,失效发生在焊缝上的趋势有所减小;当失效发生在焊缝上时,断裂面与焊缝约成90°;焊缝角度大于一定的角度时,失效发生在薄侧母材上。随着薄侧母材所占比例的增加,整体成形性能有所提高。连续变截面板随着厚度差的增大,延伸率有所降低,但仍具有较高的延伸性,且随着厚度差进一步增加会出现二次断裂现象。
②拼焊板拉伸断口形貌显示:材质为DC06的拼焊板断口均为韧窝断裂;随着焊缝角度的增加,断口中韧窝尺寸增大,且断口韧窝由等轴形韧窝变椭圆形韧窝,最后又变为等轴形韧窝。
③杯突试验表明:随着厚度的增大,母材的杯突值IE增加。同种材质的拼焊板IE值小于母材的IE值。厚度差及焊缝位置是焊缝移动的主要影响因素。
④拉深试验表明:焊缝的存在明显降低了拼焊板的整体拉深成形性能,并且在拉深的过程中焊缝处表现出明显的各向异性。焊缝两侧板材变形不均匀,从杯底中心位置到杯口位置,焊缝由向厚侧母材移动转变为向薄侧母材移动。连续变截面板的极限拉深比(LDR)随厚度差的增大呈先增大后减小的趋势,最小压边力增大,最大工作载荷减小。拼焊板与连续变截面板具有相似的成形特点,但连续变截面板具有更优越的成形性,成形质量高,应用更广泛。
⑤数值模拟结果显示:应用试验为基础的真实焊缝模型比应用简化的刚性连接焊缝模型模拟出来的结果更接近实际。数值模拟在考虑材料自身和拼焊板焊缝处所表现出来的各向异性时,与实际还存在一定的误差。
In this paper the stamping performance of variable cross section thin sheet (TWB and TRB) is researched by systematic.
First, the base material of DC06 and DC03 and the variable cross section thin sheet are used for the tensile test, the cup testing and the cup-drawing testing and the SEM testing. In order to discover the formability of TWB in different welded line condition,FEM was used to simulate the formability of the equal thickness sheets and its TWB.
①The tensile testing show that under a range of the welded line angle, the failure occurs across the weld line first. As the thickness difference increase, the failure occurs across the welded line has decreasing trend; The angle between the surface the failure and the weld line is about 90°, when the failure occurs across the weld line; The failure occurs across the thinner sheet when the angle is over certain degree. As the proportion of the thinner sheet increase, the formability of the TWB increasing. the tensile test also show that although the elongation of TRB reducing as increasing of the thickness difference, which still have better elongation, and the second rip may be happen when the thickness difference increase further.
②The SEM show that the tensile fracture types of the TWB for the material of DC06 were all dimple under different angles; the size of the dimple increase as the angle increase, and the shape of dimple become from the equiaxed dimple to elliptic dimple, and become the equiaxed dimple finally.
③The cup testing show: the IE increasing as the thickness increasing of the equal thickness sheets, and the IE of the TWB is less than the base material. The different thickness and the location of the welded line are the main influencing factors for the movement of the welded line.
④The cup-drawing testing show: the existence of the welded line, which reduce the formability of the TWB. And the anisotropy was very clear around the welded line during the drawing of TWB. The deformation both of the base material is inhomogeneity during the forming, from the bottom center to port of the cup, the welded line first move to the thick sheet then to the thinner sheet. The cup-drawing test also show that ,as the thickness difference increase, the limited drawing ratio (LDR) of TRB first up then down, the minimum BHF has increasing trend and the Maximum Working Load has decreasing trend. The TWB and the TRB have the similar forming character, but the TRB has the better formability, the better forming quality and the wildly used.
⑤The numeric simulation result show that the true welded line model based on the experiment is closer to the fact than the simple welded line model. Numeric simulation which can simulate the forming of the TWB, but the errors still exist especially in anisotropy of the main sheet and the welded line.
首先,对材质为DC06和DC03的母材及变截面板进行了拉伸试验、杯突试验、拉深试验以及断口扫描试验等基础性研究,应用数值模拟对等厚板及拼焊板成形过程进行了分析,以掌握拼焊板在不同成形条件下的变形规律。
①拉伸试验表明:拼焊板焊缝角度小于一定范围内时,失效发生在焊缝上;随着厚度差增加,失效发生在焊缝上的趋势有所减小;当失效发生在焊缝上时,断裂面与焊缝约成90°;焊缝角度大于一定的角度时,失效发生在薄侧母材上。随着薄侧母材所占比例的增加,整体成形性能有所提高。连续变截面板随着厚度差的增大,延伸率有所降低,但仍具有较高的延伸性,且随着厚度差进一步增加会出现二次断裂现象。
②拼焊板拉伸断口形貌显示:材质为DC06的拼焊板断口均为韧窝断裂;随着焊缝角度的增加,断口中韧窝尺寸增大,且断口韧窝由等轴形韧窝变椭圆形韧窝,最后又变为等轴形韧窝。
③杯突试验表明:随着厚度的增大,母材的杯突值IE增加。同种材质的拼焊板IE值小于母材的IE值。厚度差及焊缝位置是焊缝移动的主要影响因素。
④拉深试验表明:焊缝的存在明显降低了拼焊板的整体拉深成形性能,并且在拉深的过程中焊缝处表现出明显的各向异性。焊缝两侧板材变形不均匀,从杯底中心位置到杯口位置,焊缝由向厚侧母材移动转变为向薄侧母材移动。连续变截面板的极限拉深比(LDR)随厚度差的增大呈先增大后减小的趋势,最小压边力增大,最大工作载荷减小。拼焊板与连续变截面板具有相似的成形特点,但连续变截面板具有更优越的成形性,成形质量高,应用更广泛。
⑤数值模拟结果显示:应用试验为基础的真实焊缝模型比应用简化的刚性连接焊缝模型模拟出来的结果更接近实际。数值模拟在考虑材料自身和拼焊板焊缝处所表现出来的各向异性时,与实际还存在一定的误差。
In this paper the stamping performance of variable cross section thin sheet (TWB and TRB) is researched by systematic.
First, the base material of DC06 and DC03 and the variable cross section thin sheet are used for the tensile test, the cup testing and the cup-drawing testing and the SEM testing. In order to discover the formability of TWB in different welded line condition,FEM was used to simulate the formability of the equal thickness sheets and its TWB.
①The tensile testing show that under a range of the welded line angle, the failure occurs across the weld line first. As the thickness difference increase, the failure occurs across the welded line has decreasing trend; The angle between the surface the failure and the weld line is about 90°, when the failure occurs across the weld line; The failure occurs across the thinner sheet when the angle is over certain degree. As the proportion of the thinner sheet increase, the formability of the TWB increasing. the tensile test also show that although the elongation of TRB reducing as increasing of the thickness difference, which still have better elongation, and the second rip may be happen when the thickness difference increase further.
②The SEM show that the tensile fracture types of the TWB for the material of DC06 were all dimple under different angles; the size of the dimple increase as the angle increase, and the shape of dimple become from the equiaxed dimple to elliptic dimple, and become the equiaxed dimple finally.
③The cup testing show: the IE increasing as the thickness increasing of the equal thickness sheets, and the IE of the TWB is less than the base material. The different thickness and the location of the welded line are the main influencing factors for the movement of the welded line.
④The cup-drawing testing show: the existence of the welded line, which reduce the formability of the TWB. And the anisotropy was very clear around the welded line during the drawing of TWB. The deformation both of the base material is inhomogeneity during the forming, from the bottom center to port of the cup, the welded line first move to the thick sheet then to the thinner sheet. The cup-drawing test also show that ,as the thickness difference increase, the limited drawing ratio (LDR) of TRB first up then down, the minimum BHF has increasing trend and the Maximum Working Load has decreasing trend. The TWB and the TRB have the similar forming character, but the TRB has the better formability, the better forming quality and the wildly used.
⑤The numeric simulation result show that the true welded line model based on the experiment is closer to the fact than the simple welded line model. Numeric simulation which can simulate the forming of the TWB, but the errors still exist especially in anisotropy of the main sheet and the welded line.
引文
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[3]施志刚,王宏雁.变截面薄板技术在车身轻量化上的应用[J].上海汽车,2008,08:36-45.
[4]唐炳涛,王兆清,张郁.拼焊板成形零件焊缝移动的快速预测[J].锻压技术,2008,33(2):34-37.
[5]瞿丰,邓正才,姚舜等.汽车拼板的激光焊接的研究[J].焊接技术,2003,32(5):27-28.
[6] Brad Kinsey,Liu Zhi-hong.A novel forming technology for tailor-welded blanks[J].Journal of Materials Processing Technology,2000,99(1):145-153.
[7]李志远,钱乙余,张九海等.先进连接方法[M].北京:机械工业出版社,2000.
[8]杜继涛,齐从谦.变截面薄板在车身制造中的应用研究[J].锻压技术,2005,增刊:39-43.
[9] Raymond Scott D,Wild Peter M,Bayley Christopher J.On modeling of the weld line in finite element analyses of tailor-welded blank forming operations[J] . Journal of Materials Processing Technology,2004,147(1):28-37.
[10]张彦敏,张断宏,杨永顺等.拼焊板技术在汽车覆盖件中的应用[J].河南科技大学学报,2006, 27(1):27-30.
[11] Abdullah K,Wild P M.Tensile testing for weld deforming properties in similar gage tailor welded blanks using the rule of mixtures[J].Journal of Materials Processing Technology,2001,112(2001):91-97.
[12] Richard W.Davies,John S.Mechanical properties of aluminum tailor welded blanks at super-plastic temperatures[J].Journal of Materials Processing Technology,2002,128:38-47.
[13] MIN K B,KANG S S.A study on resistance welding in steel sheet for tailor welded blank evaluation of flash welded ability and formability:2nd report[J].Journal of Materials Processing Technology,2002,103:218-224.
[14] SHAKERI H R,BUSTE A.Study of damage initation and fracture in aluminum tailor welded blanks made via different welding techniques[J].Journal of Light Metals,2002,2:95-110.
[15] Wang B Y,et al.Performance of tailor welded sheet steels[J].SAE Technical Paper Series,950376:12-14.
[16]雷玉成.ST14钢激光拼焊板焊缝组织及成型性能分析[J].焊接学报,2006, 27(7):25-28.
[17]胡伦骥,刘建华,熊建钢等.汽车板激光焊工艺研究[J].钢铁研究,1995,3(84):46-50.
[18]刘建华,胡伦骥.汽车用薄钢板的激光拼焊[J].中国机械工程,1996,7(4):96-98.
[19]郑启光,秦应雄,朱蕴策等.汽车剪裁板的激光高速拼焊试验研究[J].光学技术,2002,28(5):422-426.
[20]王炳德,刘莹.拼焊板焊接法及其试验研究[J].机械设计与制造,2002,(2):105-106.
[21]瞿丰.汽车拼板的激光焊接研究[J].焊接技术,2003,32(5):27-28.
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