凸锥夹层板辊式成形工艺研究
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摘要
基于MSC.Marc有限元软件对凸锥夹层板的辊式成形过程进行了数值模拟,以夹层凸锥辊式成形后壁厚最大减薄率为成形性评价指标,研究了各主要结构参数对成形的影响。结果表明:凸模圆角半径R1、凸模转角半径R2以及摩擦系数μ对凸锥夹层板的壁厚最大减薄率影响较大,并给出了其影响规律和成形目标零件的参数建议取值。基于分析结果,设计了用于辊式成形的试验机,并进行了凸锥夹层板辊式成形实验,验证结果表明针对凸锥形夹层板辊式成形工艺的可行性,但仍存在凸锥点阵间纵向过桥位置起皱、板料纵横向翘曲、板边不齐、凸锥曲面卸载畸变等成形质量问题。
The finite element analysis of the rolling forming process of pyramid sandwich plate was performed by MSC.Marc.Taking the maximum thinning ratio of the wall thickness of pyramid sandwich plate after rolling forming as the formability evaluation index,the effect of the main structural parameters on forming process was evaluated.The results show that punch radius R1,punch corner radius R2 and friction coefficient μ have great influence on the maximum thinning ratio of wall thickness of pyramid sandwich plate.The influence rule was given and the parameters of the forming target part were suggested.Based on the analysis results,a test machine for rolling forming was designed,and rolling forming experiment of pyramid sandwich plate was carried out.The results show that the rolling forming process for the pyramid sandwich plate is feasible,but there also exist forming quality problems,such as the vertical bridge position wrinkling between the convex pyramid lattice,the longitudinal and horizontal warping of the plate,the uneven edge of the plate,the unload distortion of the convex pyramid surface and so on.
The finite element analysis of the rolling forming process of pyramid sandwich plate was performed by MSC.Marc.Taking the maximum thinning ratio of the wall thickness of pyramid sandwich plate after rolling forming as the formability evaluation index,the effect of the main structural parameters on forming process was evaluated.The results show that punch radius R1,punch corner radius R2 and friction coefficient μ have great influence on the maximum thinning ratio of wall thickness of pyramid sandwich plate.The influence rule was given and the parameters of the forming target part were suggested.Based on the analysis results,a test machine for rolling forming was designed,and rolling forming experiment of pyramid sandwich plate was carried out.The results show that the rolling forming process for the pyramid sandwich plate is feasible,but there also exist forming quality problems,such as the vertical bridge position wrinkling between the convex pyramid lattice,the longitudinal and horizontal warping of the plate,the uneven edge of the plate,the unload distortion of the convex pyramid surface and so on.
引文
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[14]李拓,江俊.点阵多孔金属夹芯板振动特性分析及优化设计[J].动力学与控制学报,2009,7(1):39-44.LI Tuo,JIANG Jun.Vibration character istics and optimization of truss-cored metal sandwich plates[J].Journal of Dynamics and Control,2009,7(1):39-44.
[15]吴林志,熊健,马力,等.轻质夹层多功能结构一体化设计[J].力学与实践,2012,34(4):8-18.WU Linzhi,XIONG Jian,MA Li,et al.Integrated design of lightweight multifunctional sandwich structures[J].Mechanics in Engineering,2012,34(4):8-18.
[16]XIONG J,MA L,PAN S,et al.Shear and bending performance of carbon fiber composite sandwich panels with pyramidal truss cores[J].Acta Materialia,2012,60(4):1455-1466.
[17]GARESCF.Static and dynamic analysis of bonded sandwich plates[J].International Journal of Adhesion&Adhesives,2012,33:7-14.
[18]ST-PIERRE L,DESHPANDE V S,FLECK N A.The low velocity impact response of sandwich beams with a corrugated core or a Y-frame core[J].International Journal of Mechanical Sciences,2015,91:71-80.
[19]赵石岩,张有为,高杨,等.斜壁盒形件滚动拉深成形工艺的有限元分析[J].塑性工程学报,2017,24(5):38-43,67.ZHAO Shiyan,ZHANG Youwei,GAO Yang,et al.Finite element analysis of the rolling drawing process of inclined wall box[J].Journal of Plasticity Engineering,2017,24(5):38-43,67.
[2]朱宏敏.汽车轻量化关键技术的应用及发展[J].应用能源技术,2009,(2):10-12.ZHU Hongmin.The application and development of key technologies in automotive weight lightening[J].Applied Engergy Technology,2009,(2):10-12.
[3]李雷,吴小俊.镁铝轻质复合板多层挤压复合工艺[J].锻压技术,2017,42(4):73-78.LI Lei,WU Xiaojun.Extrusion compound process of Mg/Al composite plate[J].Forging&Stamping Technology,2017,42(4):73-78.
[4]CRUPI V,EPASTO G,GUGLIELMINO E.Impact response of aluminum foam sandwiches for light-weight ship structures[J].Metals,2011,1(1):98-112.
[5]李毅.轻质夹层复合结构稳定性及冲击性能分析[D].西安:西北工业大学,2007.LI Yi.The stablility and impact analysis of the light sandwich structures[D].Xi'an:Northwestern Polytechnical University,2007.
[6]张乔斌,李浩,昌放辉.轻质夹层结构复合材料的制备及性能[J].舰船科学技术,2011,33(12):129-133.ZHANG Qiaobin,LI Hao,CHANG Fanghui.Preparation and performance of lightweight sandwich composite[J].Ship Science and Technology,2011,33(12):129-133.
[7]HALDAR S,BRUCK H A.Mechanics of composite sandwich structures with bioinspired core[J].Composites Science and Technology,2014,95:67-74.
[8]RAJANEESH A,SRIDHAR I,RAJENDRAN S.Relative performance of metal and polymeric foam sandwich plates under low velocity impact[J].International Journal of Impact Engineering,2014,65:126-136.
[9]杨益,李晓军,郭彦朋.夹芯材料发展及防护结构应用综述[J].兵器材料科学与工程,2010,33(4):91-96.YANG Yi,LI Xiaojun,GUO Yanpeng.Development of sandwich materials and their application overview in protective structure[J].Ordnance Material Sciencue and Engineering,2010,33(4):91-96.
[10]姜立标,刘永浩,刘金龙,等.铝蜂窝复合材料客车底板性能研究及应用[J].汽车零部件,2014,(2):26-29.JIANG Libiao,LIU Yonghao,LIU Jinlong,et al.Research and application of performance of aluminum honeycomb composite bus floor[J].Car Parts,2014,(2):26-29.
[11]HWANG J S,CHOI T G,LYU M Y,et al.Investigation for the bending modes of a semi-circular pyramidal kagome sandwich structure and the bending load calculation[J].Composite Structures,2015,134:10-17.
[12]MCSHANE G J,DESHPANDE V S,FLECK N A.Underwater blast response of free-standing sandwich plates with metallic lattice cores[J].International Journal of Impact Engineering,2010,37(11):1138-1149.
[13]FROSTIG Y,THOMSEN O.Geometrically nonlinear thermomechanical response of circular sandwich plates with a compliant core[J].Journal of Mechanics of Materials&Structures,2011,6(6):925-948.
[14]李拓,江俊.点阵多孔金属夹芯板振动特性分析及优化设计[J].动力学与控制学报,2009,7(1):39-44.LI Tuo,JIANG Jun.Vibration character istics and optimization of truss-cored metal sandwich plates[J].Journal of Dynamics and Control,2009,7(1):39-44.
[15]吴林志,熊健,马力,等.轻质夹层多功能结构一体化设计[J].力学与实践,2012,34(4):8-18.WU Linzhi,XIONG Jian,MA Li,et al.Integrated design of lightweight multifunctional sandwich structures[J].Mechanics in Engineering,2012,34(4):8-18.
[16]XIONG J,MA L,PAN S,et al.Shear and bending performance of carbon fiber composite sandwich panels with pyramidal truss cores[J].Acta Materialia,2012,60(4):1455-1466.
[17]GARESCF.Static and dynamic analysis of bonded sandwich plates[J].International Journal of Adhesion&Adhesives,2012,33:7-14.
[18]ST-PIERRE L,DESHPANDE V S,FLECK N A.The low velocity impact response of sandwich beams with a corrugated core or a Y-frame core[J].International Journal of Mechanical Sciences,2015,91:71-80.
[19]赵石岩,张有为,高杨,等.斜壁盒形件滚动拉深成形工艺的有限元分析[J].塑性工程学报,2017,24(5):38-43,67.ZHAO Shiyan,ZHANG Youwei,GAO Yang,et al.Finite element analysis of the rolling drawing process of inclined wall box[J].Journal of Plasticity Engineering,2017,24(5):38-43,67.