薄壁球面构件普旋法兰起皱预测方法评价
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摘要
为了探究现有的起皱评价方法对薄壁球面构件普旋法兰起皱发生时刻预测的精确性,以2024-O铝合金球面薄壁构件第一道次普旋为研究对象,通过试验方法确定了2024-O铝合金旋压法兰起皱发生时刻,同时结合数值仿真手段,基于现有的起皱评价方法分别得出了2024-O铝合金旋压法兰起皱发生时刻的结果.研究结果表明:法兰几何波动法和基于塑性失稳的理论模型可以正确地预测法兰起皱发生时刻,前者预测误差达到12.5%,后者误差为7.7%;旋压力法可以预测法兰严重起皱时刻,但无法定量预测起皱发生时刻;弹性应变能振荡法对上述两种起皱问题均无法预测.
In order to explore the accuracy of the existing wrinkle evaluation method for the prediction of the wrinkling of the thin-walled spherical members, the first-pass conventional spinning of the 2024-O aluminum alloy spherical thin-walled member is taken as the research object, and the test method is used to determine the occurrence of the 2024-O aluminum alloy spinning flange wrinkle, combined with the numerical simulation method, which obtains the results of the wrinkling occurrence of the 2024-O aluminum alloy spinning flange based on the existing wrinkle evaluation methods. The results show that the flange geometry wave method and the model based on plastic instability theory can correctly predict the moment when the flange wrinkles occur, and the former method's prediction error is 12.5% and the latter is 7.7%. The spin pressure method can predict the moment of serious wrinkles, but cannot quantitatively predict the occurrence time of wrinkles. The elastic strain energy oscillation method cannot predict the above two wrinkling problems.
In order to explore the accuracy of the existing wrinkle evaluation method for the prediction of the wrinkling of the thin-walled spherical members, the first-pass conventional spinning of the 2024-O aluminum alloy spherical thin-walled member is taken as the research object, and the test method is used to determine the occurrence of the 2024-O aluminum alloy spinning flange wrinkle, combined with the numerical simulation method, which obtains the results of the wrinkling occurrence of the 2024-O aluminum alloy spinning flange based on the existing wrinkle evaluation methods. The results show that the flange geometry wave method and the model based on plastic instability theory can correctly predict the moment when the flange wrinkles occur, and the former method's prediction error is 12.5% and the latter is 7.7%. The spin pressure method can predict the moment of serious wrinkles, but cannot quantitatively predict the occurrence time of wrinkles. The elastic strain energy oscillation method cannot predict the above two wrinkling problems.
引文
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[12] KONG Q S,YU Z Q,ZHAO Y X,et al.Theoretical prediction of flange wrinkling in first-pass conventional spinning of hemispherical part[J].Journal of Materials Processing Technology,2017,246:56-68.
[13] LIU J H,YANG H,LI Y Q.A study of the stress and strain distributions of first-pass conventional spinning under different roller-traces[J].Journal of Materials Processing Technology,2002,129(1-3):326-329.
[14] ARAI H.Robotic metal spinning-shear spinning using force feedback control[C]//IEEE International Conference on Robotics and Automation.IEEE,2003,3:3977-3983.
[15] WANG L,LONG H.Investigation of material deformation in multi-pass conventional metal spinning[J].Materials & Design,2011,32(5):2891-2899.
[16] 万旭敏,赵亦希,孔庆帅,等.旋压法兰起皱预测[J].上海交通大学学报,2017,51(11):1312-1319.WAN Xumin,ZHAO Yixi,KONG Qingshuai,et al.Research on prediction of flange wrinkling in conventional spinning[J].Journal of Shanghai Jiao Tong University,2017,51(11):1312-1319.
[2] ZHAN M,YANG H,GUO J,et al.Review on hot spinning for difficult-to-deform lightweight metals[J].Transactions of Nonferrous Metals Society of China,2015,25(6):1732-1743.
[3] 詹梅,李志欣,高鹏飞,等.铝合金大型薄壁异型曲面封头旋压成形研究进展[J].机械工程学报,2018(9):86-96.ZHAN Mei,LI Zhixin,GAO Pengfei,et al.Advances in spinning of aluminum alloy large-sized thin-walled and special-curved surface head[J].Journal of Mechanical Engineering,2018(9):86-96.
[4] ZHANG Y,SHAN D,XU W,et al.Study on spinning process of a thin-walled aluminum alloy vessel head with small ratio of thickness to diameter[J].Journal of Manufacturing Science and Engineering,2010,132(1):014504.
[5] ZHAN M,YANG H,ZHANG J H,et al.3D FEM analysis of influence of roller feed rate on forming force and quality of cone spinning[J].Journal of Materials Processing Technology,2007,186:486-491.
[6] XIA Q,SHIMA S,KOTERA H,et al.A study of the one-path deep drawing spinning of cups[J].Journal of Materials Processing Technology,2005,159(3):397-400.
[7] KLEINER M,G?BEL R,KANTZ H,et al.Combined methods for the prediction of dynamic instabilities in sheet metal spinning[J].CIRP Annals-Manufacturing Technology,2002,51(1):209-214.
[8] SEBASTIANI G,BROSIUS A,EWERS R,et al.Numerical investigation on dynamic effects during sheet metal spinning by explicit finite-element-analysis[J].Journal of Materials Processing Tech,2006,177(1-3):401-403.
[9] WANG L,LONG H,ASHLEY D,et al.Effects of the roller feed ratio on wrinkling failure in conventional spinning of a cylindrical cup[J].Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,2011,225(11):1991-2006.
[10] LIU C H.The simulation of the multi-pass and dieless spinning process[J].Journal of materials processing technology,2007,192:518-524.
[11] WATSON M,LONG H.Wrinkling failure mechanics in metal spinning[J].Procedia Engineering,2014,81:2391-2396.
[12] KONG Q S,YU Z Q,ZHAO Y X,et al.Theoretical prediction of flange wrinkling in first-pass conventional spinning of hemispherical part[J].Journal of Materials Processing Technology,2017,246:56-68.
[13] LIU J H,YANG H,LI Y Q.A study of the stress and strain distributions of first-pass conventional spinning under different roller-traces[J].Journal of Materials Processing Technology,2002,129(1-3):326-329.
[14] ARAI H.Robotic metal spinning-shear spinning using force feedback control[C]//IEEE International Conference on Robotics and Automation.IEEE,2003,3:3977-3983.
[15] WANG L,LONG H.Investigation of material deformation in multi-pass conventional metal spinning[J].Materials & Design,2011,32(5):2891-2899.
[16] 万旭敏,赵亦希,孔庆帅,等.旋压法兰起皱预测[J].上海交通大学学报,2017,51(11):1312-1319.WAN Xumin,ZHAO Yixi,KONG Qingshuai,et al.Research on prediction of flange wrinkling in conventional spinning[J].Journal of Shanghai Jiao Tong University,2017,51(11):1312-1319.
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