筒形件多道次普通缩旋三维弹塑性有限元模拟研究
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摘要
多道次普旋作为一种金属塑性加工方法，在航空、航天、兵器等领域
中得到了日益广泛的应用，但是理论上的系统研究迄今仍然是一个薄弱环
节，旋轮运动轨迹的选取依然是依靠经验数据和现场试验。因此，开展多
道次普旋成形理论的研究是当前旋压技术发展中一项迫切的研究课题，对
提高多道次普旋成形极限、成形质量与加工效率，以及开发新产品具有重
要的实用价值。本文着重采用计算机数值模拟，并与理论分析相结合，对
多道次普旋中具有代表性的方式—筒形件多道次无芯模缩旋进行了三维弹
塑性有限元数值模拟研究，并对多道次旋轮运动轨迹的确定方法进行了初
步探讨。主要研究内容和结果如下：
对筒形件多道次缩旋建立了符合实际的三维弹塑性有限元变形力学模型；
对其三维弹塑性有限元模拟分析中所涉及的空间斜约束动态边界条件与局部
加载卸载等关键技术问题进行了系统研究，提出了有效的处理方法；采用
波前法求解方程，使得在微机上进行较大规模弹塑性有限元分析成为可能。
自行开发了筒形件多道次缩旋的三维弹塑性有限元模拟系统3D-
CSPIN。该软件具有较完善的前、后处理功能；采用模块化结构设计，易
于扩充，也可向其它具有局部加载卸载特征的金属塑性成形问题的有限元
分析推广。
采用八节点六面体三维等参元，将整个变形体划分为2160个节点，1512
个单元，利用所开发的3D-CSPIN模拟系统对筒形件多道次缩旋变形过程进行
了数值模拟，求出了旋压过程中变形区的应力、应变，揭示了其应力应变分布
规律，分析结果反映了该旋压变形局部加载局部塑性变形的特征。
对筒形件多道次缩旋旋轮运动轨迹的确定做了初步研究，提出了以所开发
的3D-CSPIN模拟系统为工作平台，以计算机数值模拟为主要技术手段的研究
思路和方法，为进一步的研究工作明确了方向。
Multi-process conventional spinning used as a method of metal plastic
forming has been widely applied in fields of aeronautics, astronautics and
weaponry. However, up to now, there has been so insufficient theoretical study
of the process that the selection of roller motion locus still depends on trial-and-
errors. So research on the forming law of Multi-process conventional spinning is
one of the important subjects in the development of spinning technology. The
research is of a significant practical value for improving forming limits, part
quality, processing efficiency, and developing new products. In this dissertation,
using a method of computer numerical simulation combined with theoretical
analysis, research on 3-D elasto-plastic FEM numerical simulation has been
carried out for multi-process neck spinning, a typical method in multi-process
conventional spinning. In addition, a method of determining multi-process roller
motion locus has been preliminarily explored. A brief introduction to the project
and its main results are as follows:
A mechanical model corresponding to reality has been established for 3-D
elasto-plastic FEM numerical simulation of multi-process neck spinning of tube.
Key techniques of the 3-D elasto-plastic FEM numerical simulation have been
studied systematically, including space inclined constraint, dynamic boundary
conditions and local loading and unloading etc, and some method to effectively
treat those problems have been proposed. Frontal solution used in the simulation
makes it possible to solve larger elasto-plastic forming problems such as multi-
process conventional spinning on a microcomputer.
A 3-D simulation system?D-CSPIN based on 3-D elasto-plastic FEM
oriented to multi-process neck spinning of tube has been developed in the
dissertation by using a modular approach which has a friendly function in pre-
treatment and post-treatment and can be easily extended and expanded. The
system can also be popularized to other finite element analysis of metal plastic
forming with local loading and unloading problems.
The eight-node hexahedron isoparametric element is used to mesh the
?The project is supported by the Foundation of National Key Laboratory of Defense Science and
Technology for Precision Hot Processing of Metals of China (grant No 98JS61 .2.1 .HKO3 14)and
the Aeronautical Science Foundation of China(grant No 00H53075).
?II ?
whole deforming body into 2160 nodes and 1512 elements. By using the 3D-
CSPIN system for simulation of multi-process conventional spinning, the stress
and strain of deforming zone has been obtained, furthermore, the stress and
strain distribution law has been revealed, which shows the characteristic of local
loading and plastic deforming.
How to determine reasonable multi-process roller motion locus has been
preliminarily explored and a method proposed is the following. Establishing a
work platform based on the 3D-MSPI7N system, computer simulation is used as a
principal technical means to carry out determining multi-process roller motion
locus, which makes clear the direction of further study for the roller motion
locus.
中得到了日益广泛的应用，但是理论上的系统研究迄今仍然是一个薄弱环
节，旋轮运动轨迹的选取依然是依靠经验数据和现场试验。因此，开展多
道次普旋成形理论的研究是当前旋压技术发展中一项迫切的研究课题，对
提高多道次普旋成形极限、成形质量与加工效率，以及开发新产品具有重
要的实用价值。本文着重采用计算机数值模拟，并与理论分析相结合，对
多道次普旋中具有代表性的方式—筒形件多道次无芯模缩旋进行了三维弹
塑性有限元数值模拟研究，并对多道次旋轮运动轨迹的确定方法进行了初
步探讨。主要研究内容和结果如下：
对筒形件多道次缩旋建立了符合实际的三维弹塑性有限元变形力学模型；
对其三维弹塑性有限元模拟分析中所涉及的空间斜约束动态边界条件与局部
加载卸载等关键技术问题进行了系统研究，提出了有效的处理方法；采用
波前法求解方程，使得在微机上进行较大规模弹塑性有限元分析成为可能。
自行开发了筒形件多道次缩旋的三维弹塑性有限元模拟系统3D-
CSPIN。该软件具有较完善的前、后处理功能；采用模块化结构设计，易
于扩充，也可向其它具有局部加载卸载特征的金属塑性成形问题的有限元
分析推广。
采用八节点六面体三维等参元，将整个变形体划分为2160个节点，1512
个单元，利用所开发的3D-CSPIN模拟系统对筒形件多道次缩旋变形过程进行
了数值模拟，求出了旋压过程中变形区的应力、应变，揭示了其应力应变分布
规律，分析结果反映了该旋压变形局部加载局部塑性变形的特征。
对筒形件多道次缩旋旋轮运动轨迹的确定做了初步研究，提出了以所开发
的3D-CSPIN模拟系统为工作平台，以计算机数值模拟为主要技术手段的研究
思路和方法，为进一步的研究工作明确了方向。
Multi-process conventional spinning used as a method of metal plastic
forming has been widely applied in fields of aeronautics, astronautics and
weaponry. However, up to now, there has been so insufficient theoretical study
of the process that the selection of roller motion locus still depends on trial-and-
errors. So research on the forming law of Multi-process conventional spinning is
one of the important subjects in the development of spinning technology. The
research is of a significant practical value for improving forming limits, part
quality, processing efficiency, and developing new products. In this dissertation,
using a method of computer numerical simulation combined with theoretical
analysis, research on 3-D elasto-plastic FEM numerical simulation has been
carried out for multi-process neck spinning, a typical method in multi-process
conventional spinning. In addition, a method of determining multi-process roller
motion locus has been preliminarily explored. A brief introduction to the project
and its main results are as follows:
A mechanical model corresponding to reality has been established for 3-D
elasto-plastic FEM numerical simulation of multi-process neck spinning of tube.
Key techniques of the 3-D elasto-plastic FEM numerical simulation have been
studied systematically, including space inclined constraint, dynamic boundary
conditions and local loading and unloading etc, and some method to effectively
treat those problems have been proposed. Frontal solution used in the simulation
makes it possible to solve larger elasto-plastic forming problems such as multi-
process conventional spinning on a microcomputer.
A 3-D simulation system?D-CSPIN based on 3-D elasto-plastic FEM
oriented to multi-process neck spinning of tube has been developed in the
dissertation by using a modular approach which has a friendly function in pre-
treatment and post-treatment and can be easily extended and expanded. The
system can also be popularized to other finite element analysis of metal plastic
forming with local loading and unloading problems.
The eight-node hexahedron isoparametric element is used to mesh the
?The project is supported by the Foundation of National Key Laboratory of Defense Science and
Technology for Precision Hot Processing of Metals of China (grant No 98JS61 .2.1 .HKO3 14)and
the Aeronautical Science Foundation of China(grant No 00H53075).
?II ?
whole deforming body into 2160 nodes and 1512 elements. By using the 3D-
CSPIN system for simulation of multi-process conventional spinning, the stress
and strain of deforming zone has been obtained, furthermore, the stress and
strain distribution law has been revealed, which shows the characteristic of local
loading and plastic deforming.
How to determine reasonable multi-process roller motion locus has been
preliminarily explored and a method proposed is the following. Establishing a
work platform based on the 3D-MSPI7N system, computer simulation is used as a
principal technical means to carry out determining multi-process roller motion
locus, which makes clear the direction of further study for the roller motion
locus.
引文
[1] Matsunok．Recent Research and Development in Metal Forming in Japan． Journal of Materials Processing Technology．1997，6：1-3
[2] 王仲仁，海锦涛．世纪之交的塑性加工技术．见：海锦涛，张立斌，陆辛．先 进制造技术．北京，1996． 北京：机械工业出版社，1996：48-50
[3] 俞新陆．21世纪塑性加工面临的挑战-对几个问题的看法．塑性加工学 报．1994，1(1) ：20-24
[4] Huang Z J，Chen D H，and Lei Y Z．Developing Tendency of Research on Technology of Plasticity from the Viewpoint ofNSFC．in：Wang Z R and He Y X eds．Advanced Technology of Plasticity 1993． Beijing，1993，Beijing： International Academic Publishers．1993：315-319
[5] 日本塑性加工学会．旋压成形技术．陈敬之译．北京：机械工业出版社， 1988：30-47
[6] S．Kalpakjian．Maximum Reduction in Power Spinning of tubes．Trans． ASME．J．Eng．Ind．，1964，86(2) ：49-54
[7] P. Bennich．Tube Spinning．Int．Journal Prod．Res．1976，14(1) ：11～21
[8] M．M．EL-KHABEERY,M．FATTOUH，M．N．E；-SHEIKH．On the Conventional Simple Spinning of Cylindrical Aluminum Cups．International Jouranal of Machine Tools&Manufacture．1991(2) ：203-219
[9] S．Kalpakjian，S．Rojagopal．Spinning of Tube：A Review．Journal of Applied Metal Working．1982，2(3) ：211-223
[10] Micha Gur,Jehuda Tirosh．Plastic Flow Instability under Compressive Loading during Shear Spinning Process．Transactions of the ASME．Journal of Engineering for Industry．1982(104) ：17-22
[11] Masujiro Hayama，Hiroaki Kudo．Experimental Study of Tube Spinning． Bulletin of the JSME．1979，22(167) ：769-775
[12] 王成和，刘克璋．旋压技术．北京：机械工业出版社，1986：1-51， 462-472，613-683
[13] 徐洪烈．强力旋压技术．北京：国防工业出版社，1984： 1-7， 21-66，161-205
[14] 陈毓勋，赵振铎，王同海．特种冲压模具与成形技术．北京：现代出版 社，1989：366-395
[15] 王仲仁．特种塑性成形．北京：机械工业出版社，1995： 119-136， 139-140
[16] 王强．普通旋压的弹塑性有限元分析及变形机理研究：[博士学位论文]． 哈尔滨：哈尔滨工业大学，1990
[17] 李云生，邢吉丰．国内普通旋压技术概况．锻压机械．1984，(4) ：29-32
[18] 夏萼辉，游秀华，肖晓青．筒形件强力旋压CAD／CAM系统．锻压机械． 1999，(1) ：48～49
[19] M．Jajazi，G．Ebrahimi．The Influence of Flow-forming Parameters and Microstructure on the Quality of a D6ac Steel．Journal of Materials Processing Technology．2000(103) ：362-366
[20] 吕雪梅，杨玉英，吕炎．三旋轮缩旋变形实验研究．锻压技术．1998，(4) ： 38-43
[21] Wang Qiang，z．R．Wang．Numerical Simulation and Experimental Study on the New Process of Two-Roller Bending Spinning．Advanced Technology of Plasticity 1993-Proceeding of the Fourth International Conference on Technology of Plasticity．Vol．3：1387-1390
[22] 康达昌，高西成，孟晓峰等．平板毛坯普旋变形方式的研究．塑性工程 学报．1998，5(4) ：102-106
[23] Zhao Yunhao，Zhang Shunfu．The Shear Spinning of Flanged Container Head． Advanced Technology of Plasticity 1993-Proceeding of the Fourth International Conference on Technology of Plasticity．Vol．3：1436-1438
[24] Zhao Xianming，Lu Yan，Wang Tao．Optimization of the Technical Parameters and Test Research on Stagger Spinning．Advanced Technology of Plasticity 1993-Proceeding of the Fourth International Conference on Technology of Plasticity．Vol．3：1426-1431
[25] 贾文铎．缩旋的走刀方式．锻压技术．1987，5：33-37
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[49] 李克智．筒形件强力旋压三维弹塑性有限元数值模拟：[博士学位论文]． 哈尔滨：哈尔滨工业大学，1996
[50] 希望，AutoCAD 10． 0计算机绘图软件包(上册)．北京：海洋出版社， 1991： 423-440
[2] 王仲仁，海锦涛．世纪之交的塑性加工技术．见：海锦涛，张立斌，陆辛．先 进制造技术．北京，1996． 北京：机械工业出版社，1996：48-50
[3] 俞新陆．21世纪塑性加工面临的挑战-对几个问题的看法．塑性加工学 报．1994，1(1) ：20-24
[4] Huang Z J，Chen D H，and Lei Y Z．Developing Tendency of Research on Technology of Plasticity from the Viewpoint ofNSFC．in：Wang Z R and He Y X eds．Advanced Technology of Plasticity 1993． Beijing，1993，Beijing： International Academic Publishers．1993：315-319
[5] 日本塑性加工学会．旋压成形技术．陈敬之译．北京：机械工业出版社， 1988：30-47
[6] S．Kalpakjian．Maximum Reduction in Power Spinning of tubes．Trans． ASME．J．Eng．Ind．，1964，86(2) ：49-54
[7] P. Bennich．Tube Spinning．Int．Journal Prod．Res．1976，14(1) ：11～21
[8] M．M．EL-KHABEERY,M．FATTOUH，M．N．E；-SHEIKH．On the Conventional Simple Spinning of Cylindrical Aluminum Cups．International Jouranal of Machine Tools&Manufacture．1991(2) ：203-219
[9] S．Kalpakjian，S．Rojagopal．Spinning of Tube：A Review．Journal of Applied Metal Working．1982，2(3) ：211-223
[10] Micha Gur,Jehuda Tirosh．Plastic Flow Instability under Compressive Loading during Shear Spinning Process．Transactions of the ASME．Journal of Engineering for Industry．1982(104) ：17-22
[11] Masujiro Hayama，Hiroaki Kudo．Experimental Study of Tube Spinning． Bulletin of the JSME．1979，22(167) ：769-775
[12] 王成和，刘克璋．旋压技术．北京：机械工业出版社，1986：1-51， 462-472，613-683
[13] 徐洪烈．强力旋压技术．北京：国防工业出版社，1984： 1-7， 21-66，161-205
[14] 陈毓勋，赵振铎，王同海．特种冲压模具与成形技术．北京：现代出版 社，1989：366-395
[15] 王仲仁．特种塑性成形．北京：机械工业出版社，1995： 119-136， 139-140
[16] 王强．普通旋压的弹塑性有限元分析及变形机理研究：[博士学位论文]． 哈尔滨：哈尔滨工业大学，1990
[17] 李云生，邢吉丰．国内普通旋压技术概况．锻压机械．1984，(4) ：29-32
[18] 夏萼辉，游秀华，肖晓青．筒形件强力旋压CAD／CAM系统．锻压机械． 1999，(1) ：48～49
[19] M．Jajazi，G．Ebrahimi．The Influence of Flow-forming Parameters and Microstructure on the Quality of a D6ac Steel．Journal of Materials Processing Technology．2000(103) ：362-366
[20] 吕雪梅，杨玉英，吕炎．三旋轮缩旋变形实验研究．锻压技术．1998，(4) ： 38-43
[21] Wang Qiang，z．R．Wang．Numerical Simulation and Experimental Study on the New Process of Two-Roller Bending Spinning．Advanced Technology of Plasticity 1993-Proceeding of the Fourth International Conference on Technology of Plasticity．Vol．3：1387-1390
[22] 康达昌，高西成，孟晓峰等．平板毛坯普旋变形方式的研究．塑性工程 学报．1998，5(4) ：102-106
[23] Zhao Yunhao，Zhang Shunfu．The Shear Spinning of Flanged Container Head． Advanced Technology of Plasticity 1993-Proceeding of the Fourth International Conference on Technology of Plasticity．Vol．3：1436-1438
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