帽形件链模成形仿真与试验研究
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摘要
通过数值模拟与成形试验的方法,研究多道次链模成形帽形件的可行性。建立了多道次链模成形帽形件的有限元模型,研究了成形过程中应力、应变的分布情况及发展历程,并估算了各道次机架的工作载荷。基于仿真结果,开发了多道次链模成形试验机,进行了帽形件的成形试验,结果发现,成形过程中未出现圆角破裂,成形效果良好。最后,将试验结果分别与仿真结果和目标形状进行对比发现,虽然腹板区域仍然存在轻微成形质量问题,但翻折角和压深的误差分别被控制在1°和0. 5 mm以下,成形目标基本实现,通过对比既验证了仿真模型的准确性,也说明成形方案的可行性。
By means of numerical simulation and forming test,the feasibility of multi-pass chain-die forming for hat-shaped part was studied,and the finite element model of multi-pass chain-die forming for hat-shaped part was established. Then,the distribution and development history of stress and strain in the forming process were studied,and the working loads of machine frame for each pass were estimated.Based on the simulation results,a testing machine of multi-pass chain-die forming was developed,and the forming test of hat-shaped part was carried out. The result shows that no fracture occurs on fillets during the forming process,and the final shape is fine. Finally,by comparing the test results with the simulation results and the target shapes respectively,although a slight forming quality problem is found at the web area,but the errors of folding angle and pressing depth are controlled below 1° and 0. 5 mm respectively,and the forming goal is basically achieved. By comparison,the accuracy of simulation model is verified,and the feasibility of forming scheme is also demonstrated.
By means of numerical simulation and forming test,the feasibility of multi-pass chain-die forming for hat-shaped part was studied,and the finite element model of multi-pass chain-die forming for hat-shaped part was established. Then,the distribution and development history of stress and strain in the forming process were studied,and the working loads of machine frame for each pass were estimated.Based on the simulation results,a testing machine of multi-pass chain-die forming was developed,and the forming test of hat-shaped part was carried out. The result shows that no fracture occurs on fillets during the forming process,and the final shape is fine. Finally,by comparing the test results with the simulation results and the target shapes respectively,although a slight forming quality problem is found at the web area,but the errors of folding angle and pressing depth are controlled below 1° and 0. 5 mm respectively,and the forming goal is basically achieved. By comparison,the accuracy of simulation model is verified,and the feasibility of forming scheme is also demonstrated.
引文
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[10]王厚高,苏春建,杨龙允.3004Al帽形钣金件基于优化函数协同变横向辊距[J].塑性工程学报,2017,24(6):24-31.Wang H G,Su C J,Yang L Y.Study on roll bending technology of 3004Al cap-shaped sheet metal based on optimized function and coordinate variable transverse roll distance technology[J].Journal of Plasticity Engineering,2017,24(6):24-31.
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[12]Zhang Y,Ding S.A comparison study of chain-die forming and roll forming by forming a top hat section[A].14th International Conference on Metal Forming[C].Germany,2012.
[2]Li Y,Sun Y,Xiao H,et al.A numerical study on chain-die forming of the AHSS U-channel and contrast with roll forming[J].International Journal of Mechanical Sciences,2018,135:279-293.
[3]韩飞,王秀坤,孙勇,等.链模式变截面成形机理分析[J].塑性工程学报,2017,24(2):22-27.Han F,Wang X K,Sun Y,et al.Mechanism of plastic deformation in chain die forming of variable cross section[J].Journal of Plasticity Engineering,2017,24(2):22-27.
[4]黄慧琳,李亚光,丁士超,等.高强度U型槽钢链模成形有限元仿真分析[J].塑性工程学报,2017,24(6):8-13.Huang H L,Li Y G,Ding S C,et al.Finite element simulation of chain-die forming for U-profiled advanced high strength steel products[J].Journal of Plasticity Engineering,2017,24(6):8-13.
[5]Tekkaya A E,Khalifa N B,Grzancic G,et al.Forming of lightweight metal components:Need for new technologies[J].Procedia Engineering,2014,81:28-37.
[6]张学广,卢锴钧,何广忠,等.材料性能波动对板材折弯回弹的影响规律研究[J].航空制造技术,2018,61(18):48-52,66.Zhang X G,Lu K J,He G Z,et al.Material properties fluctuation effects on bending springback of high strength steel[J].Aeronautical Manufacturing Technology,2018,61(18):48-52,66.
[7]王飞,游有鹏.钣金V形折弯回弹影响因素的有限元分析[J].沈阳工业大学学报,2012,34(5):526-529,535.Wang F,You Y P.Finite element analysis on influencing factors of springback in sheet metal V-bending[J].Journal of Shenyang University of Technology,2012,34(5):526-529,535.
[8]Shamoto E,Moriwaki T.Ultraprecision diamond cutting of hardened steel by applying elliptical vibration cutting[J].CIRP AnnalsManufacturing Technology,1999,48(1):441-444.
[9]小奈弘,刘继英.冷弯成型技术[M].北京:化学工业出版社,2008.Hiroshi O,Liu J Y.Cold Roll Forming Technology[M].Beijing:Chemical Industry Press,2008.
[10]王厚高,苏春建,杨龙允.3004Al帽形钣金件基于优化函数协同变横向辊距[J].塑性工程学报,2017,24(6):24-31.Wang H G,Su C J,Yang L Y.Study on roll bending technology of 3004Al cap-shaped sheet metal based on optimized function and coordinate variable transverse roll distance technology[J].Journal of Plasticity Engineering,2017,24(6):24-31.
[11]Suresh K,Praveen Kumar G,Priyadarshini A,et al.Analysis of formability in incremental forming processes[J].Materials Today:Proceedings,2018,5:18905-18910.
[12]Zhang Y,Ding S.A comparison study of chain-die forming and roll forming by forming a top hat section[A].14th International Conference on Metal Forming[C].Germany,2012.