树脂板多点热成形过程数值模拟与工艺参数优化
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摘要
介绍了树脂板多点热成形的原理,建立了PC-DSGZ本构模型,基于不同温度和应变率时PC板的真实应力-应变曲线数据,获得PC-DSGZ模型的参数。开展了球面件多点热成形数值模拟,分析了成形过程变形和压痕现象,探讨了成形温度、成形压强、冲头数量和冲头半径对成形精度的影响,结果表明:成形温度越高或成形压强越大,成形件越贴近多点模具,平均形状误差越小;冲头数量越多或冲头半径越大,成形件厚向应变波动越小,压痕越轻微。开展了PC板多点热成形试验,获得了形状轮廓和表面精度较好的球面试验件。试验结果验证了树脂板多点热成形的可行性和数值模拟的正确性。
The principle of multi-point thermoforming for resin sheet was introduced,the PC-DSGZ constitutive model was set up,and the model parameters were obtained based on real stress-strain curves of PC species with different temperatures and strain ratios. The numerical simulation for spherical part with multi-point thermoforming was carried out,the deformation of forming process and dimple phenomenon were analyzed,and the effects of forming temperature,forming pressure,punch number and punch radius on forming accuracy were investigated. The results show that the higher the forming temperature is,or the larger the forming pressure is,the smaller space between multi-point die and sheet is,and the smaller the average shape error is. The more the punch number is,or the larger the punch radius is,the smaller the fluctuation of thickness strain is,and the slighter the dimple is. The multi-point thermoforming tests of PC sheet were carried out,and the spherical part with good shape outline and surface accuracy was obtained. The feasibility of multi-point thermoforming for resin sheet and the validity of simulated results are verified by experimental result.
The principle of multi-point thermoforming for resin sheet was introduced,the PC-DSGZ constitutive model was set up,and the model parameters were obtained based on real stress-strain curves of PC species with different temperatures and strain ratios. The numerical simulation for spherical part with multi-point thermoforming was carried out,the deformation of forming process and dimple phenomenon were analyzed,and the effects of forming temperature,forming pressure,punch number and punch radius on forming accuracy were investigated. The results show that the higher the forming temperature is,or the larger the forming pressure is,the smaller space between multi-point die and sheet is,and the smaller the average shape error is. The more the punch number is,or the larger the punch radius is,the smaller the fluctuation of thickness strain is,and the slighter the dimple is. The multi-point thermoforming tests of PC sheet were carried out,and the spherical part with good shape outline and surface accuracy was obtained. The feasibility of multi-point thermoforming for resin sheet and the validity of simulated results are verified by experimental result.
引文
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[2]史国力,李复生,田红兵.聚碳酸酯在汽车和航空透明材料领域应用的研究进展[J].材料导报,2006,20(f5):404-407.SHI Guoli,LI Fusheng,TIAN Hongbing. Advances and application of polycarbonate in automobile windows and aero glass[J].Materials Review,2006,20(f5):404-407.
[3]李明哲,中村敬一.基本的な成形原理の检讨(第一报:板材多点成形法の研究)[C]//平成4年度日本塑性加工春季講演会论文集,横浜,1992:519-522.LI Mingzhe,NAKAMURA K. Study of the basic principles(1st report:Research on Multi-point forming for sheet metal)[C]//Proceedings of the Japanese Spring Conference for Technology of Plasticity,Yokohama,1992:519-522.
[4]李明哲,蔡中义,崔相吉.多点成形——金属板材柔性成形的新技术[J].金属成形工艺,2002,20(6):5-9.LI Mingzhe,CAI Zhongyi,CUI Xiangji. Multi-point forming—A new flexible forming process for sheet metal[J]. Metal Forming Technology,2002,20(6):5-9.
[5]汪华,周贤宾.飞机蒙皮多点成形用复合柔性垫层的结构参数优化[J].航空学报,2007,28(6):1482-1486.WANG Hua,ZHOU Xianbin. Structure parameters optimization on composite flexible pad for aircraft skin stretch forming with reconfigurable tool[J]. Acta Aeronautica et Astronautica Sinica,2007,28(6):1482-1486.
[6] TAN F X,LI M Z,CAI Z Y. Research on the process of multipoint forming for the customized titanium alloy cranial prosthesis[J]. Journal of Materials Processing Technology,2007,s 187-188(4):453-457.
[7]韩奇钢,付文智,冯朋晓,等.多点成形技术的研究进展及应用现状[J].航空制造技术,2010,(24):87-89.HAN Qigang,FU Wenzhi,FENG Pengxiao,et al. Research development and application of multi-point forming technology[J].Aeronautical Manufacturing Technology,2010,(24):87-89.
[8] DUAN Y P,SAIGAL A,GREIF R. Impact behavior and modeling of engineering polymers[J]. Polymers Engineering and Science,2003,43:112-124.