基于韧性断裂准则的铝合金壁板多点成形断裂预测
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摘要
基于韧性断裂准则,预测了单筋条试件和多筋条试件多点压弯成形中的断裂位置和启裂时刻,并进行了多点压弯实验。对比分析结果显示:预测的试件断裂位置与实验基本一致,启裂时刻对应的上模临界下压量与实验相比,误差在10%以内。分析了不同筋条试件多点成形中断裂产生的原因,针对腹板在变形量过大时易出现断裂、难成形的问题,提出了整体壁板试件多道次成形方法。仿真结果显示,多道次多点成形能抑制壁板断裂。
In this paper,fracture position and fracture moment on single stiffener and multi-stiffener workpieces were predicted using finite element method based on fracture ductile criterion,and multipoint press bending experiments were conducted.It is found that the predicted fracture position is consistent with that of the experiments.The error of punch displacement at fracture moment is less than 10% compared with experimental results.The fracture reason of different stiffeners were analyzed based on the ductile fracture mechanics.To solve the problem that the web is easily to fracture when deformation is large,a multi-step forming method was proposed.Simulation results show that the proposed method can restrain the fracture on integral panel workpiece.
In this paper,fracture position and fracture moment on single stiffener and multi-stiffener workpieces were predicted using finite element method based on fracture ductile criterion,and multipoint press bending experiments were conducted.It is found that the predicted fracture position is consistent with that of the experiments.The error of punch displacement at fracture moment is less than 10% compared with experimental results.The fracture reason of different stiffeners were analyzed based on the ductile fracture mechanics.To solve the problem that the web is easily to fracture when deformation is large,a multi-step forming method was proposed.Simulation results show that the proposed method can restrain the fracture on integral panel workpiece.
引文
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[13]方刚,雷丽萍,曾攀.金属塑性成形过程延性断裂的准则及其数值模拟[J].机械工程学报,2002,38(增刊1):21-25.Fang Gang,Lei Li-ping,Zeng Pan.Criteria of metal ductile fracture and numerical simulation for metal forging[J].Chinese Journal of Mechanical Engineering,2002,38(Sup.1):21-25.
[14]Wang Z J,Li Y,Liu J G,et al.Evaluation of forming limit in viscous pressure forming of automotive aluminum alloy 6k21-T4sheet[J].Transactions of Nonferrous Metals Society of China,2007,17(6):1169-1174.
[15]杨玉英,于忠奇,王永志,等.应用韧性断裂准则预测盒形件拉深成形极限[J].哈尔滨工业大学学报,2004,36(11):1507-1510.Yang Yu-ying,Yu Zhong-qi,Wang Yong-zhi,et al.The application of a ductile fracture criterion to the prediction of the forming limit in quadrate-cup deep drawing[J].Journal of Harbin Institute of Technology,2004,36(11):1507-1510.
[16]黄建科,董湘怀.金属韧性断裂准则的数值模拟和试验研究[J].材料科学与工艺,2010,18(4):450-454.Huang Jian-ke,Dong Xiang-huai.Numerical simulation and experimental verification of ducile fracture criteria of metals[J].Materials Science&Technology,2010,18(4):450-454.
[17]朱浩,朱亮,陈剑虹.铝合金在三种应力状态下的力学性能研究及断口分析[J].兰州理工大学学报,2006,32(6):28-31.Zhu Hao,Zhu Liang,Chen Jian-hong.Study of mechanical performance and analysis of fracture surfaces of aluminum alloy in three patterns of stress state[J].Journal of Lanzhou University of Technology,2006,32(6):28-31.
[18]钱直睿,李明哲,谭富星.多点压机成形与多道次多点模具成形的数值模拟研究[J].塑性工程学报,2007,14(3):20-23.Qian Zhi-rui,Li Ming-zhe,Tan Fu-xing.Numerical simulation study on the process of multi-point press forming and multi-step multi point die forming[J].Journal of Plasticity Engineering,2007,14(3):20-23.
[19]Cai Z,Li M.Optimum path forming technique for sheet metal and its realization in multi-point forming[J].Journal of Materials Processing Technology,2001,110(2):136-141.
[2]刘纯国,蔡中义,李明哲.多点成形中压痕的形成与控制方法[J].吉林大学学报:工学版,2004,34(1):91-96.Liu Chun-guo,Cai Zhong-yi,Li Ming-zhe,et al.Dimple formation and its elimination in multi-point forming for sheet metal[J].Journal of Jilin University(Engineering and Technology Edition),2004,34(1):91-96.
[3]庄蔚敏,曹德闯,叶辉.基于连续介质损伤力学预测7075铝合金热冲压成形极限图[J].吉林大学学报:工学版,2014,44(2):409-414.Zhuang Wei-min,Cao De-chuang,Ye Hui.Prediction of FLD for AA7075under hot stamping based on continuum damage mechanics[J].Journal of Jilin University(Engineering and Technology Edition),2014,44(2):409-414.
[4]Panich S,Barlat F,Uthaisangsuk V,et al.Experimental and theoretical formability analysis using strain and stress based forming limit diagram for advanced high strength steels[J].Materials&Design,2013,51(5):756-766.
[5]Safikhani A R,Hashemi R,Assempour A.The strain gradient approach for determination of forming limit stress and strain diagrams[J].Proceedings of the Institution of Mechanical Engineers Part B:Journal of Engineering Manufacture,2008,222(4):467-483.
[6]Yan Y,Wang H B,Wan M.Prediction of fracture in press bend forming of aluminum alloy highstiffener integral panels[J].Computational Materials Science,2011,50(7):2232-2244.
[7]Takuda H,Mori K,Fujimoto H,et al.Prediction of forming limit in bore-expanding of sheet metals using ductile fracture criterion[J].Journal of Materials Processing Technology,1999(92/93):433-438.
[8]Takuda H,Yoshii T,Hatta N.Finite element analysis of the formability of a magnesium-based alloy AZ31 sheet[J].Journal of Materials Processing Technology,1999(89/90):135-140.
[9]Takuda H,Mori K,Takakura N,et al.Finite element analysis of limit strains in biaxial stretching of sheet metals allowing for ductile fracture[J].Int J Mech Sci,2000,42(4):785-798.
[10]Goijaerts A M,Govaert L E,Baaijens F P T.Prediction of ductile fracture in metal blanking[J].Journal of Manufacturing Science and Engineering,2000,122(3):476-483.
[11]Shim K H,Lee S K,Kang B S,et al.Investigation on blanking of thin sheet metal using the ductile fracture criterion and its experimental verification[J].Journal of Materials Processing Technology,2004,155(1):1935-1942.
[12]方刚,曾攀.金属板材冲裁过程的有限元模拟[J].金属学报,2001,37(6):653-657.Fang Gang,Zeng Pan.Finite element simulation for blanking process of sheet metal[J].Acta Metallurgica Sinica,2001,37(6):653-657.
[13]方刚,雷丽萍,曾攀.金属塑性成形过程延性断裂的准则及其数值模拟[J].机械工程学报,2002,38(增刊1):21-25.Fang Gang,Lei Li-ping,Zeng Pan.Criteria of metal ductile fracture and numerical simulation for metal forging[J].Chinese Journal of Mechanical Engineering,2002,38(Sup.1):21-25.
[14]Wang Z J,Li Y,Liu J G,et al.Evaluation of forming limit in viscous pressure forming of automotive aluminum alloy 6k21-T4sheet[J].Transactions of Nonferrous Metals Society of China,2007,17(6):1169-1174.
[15]杨玉英,于忠奇,王永志,等.应用韧性断裂准则预测盒形件拉深成形极限[J].哈尔滨工业大学学报,2004,36(11):1507-1510.Yang Yu-ying,Yu Zhong-qi,Wang Yong-zhi,et al.The application of a ductile fracture criterion to the prediction of the forming limit in quadrate-cup deep drawing[J].Journal of Harbin Institute of Technology,2004,36(11):1507-1510.
[16]黄建科,董湘怀.金属韧性断裂准则的数值模拟和试验研究[J].材料科学与工艺,2010,18(4):450-454.Huang Jian-ke,Dong Xiang-huai.Numerical simulation and experimental verification of ducile fracture criteria of metals[J].Materials Science&Technology,2010,18(4):450-454.
[17]朱浩,朱亮,陈剑虹.铝合金在三种应力状态下的力学性能研究及断口分析[J].兰州理工大学学报,2006,32(6):28-31.Zhu Hao,Zhu Liang,Chen Jian-hong.Study of mechanical performance and analysis of fracture surfaces of aluminum alloy in three patterns of stress state[J].Journal of Lanzhou University of Technology,2006,32(6):28-31.
[18]钱直睿,李明哲,谭富星.多点压机成形与多道次多点模具成形的数值模拟研究[J].塑性工程学报,2007,14(3):20-23.Qian Zhi-rui,Li Ming-zhe,Tan Fu-xing.Numerical simulation study on the process of multi-point press forming and multi-step multi point die forming[J].Journal of Plasticity Engineering,2007,14(3):20-23.
[19]Cai Z,Li M.Optimum path forming technique for sheet metal and its realization in multi-point forming[J].Journal of Materials Processing Technology,2001,110(2):136-141.