基于增量控制的型材拉弯轨迹设计及有限元仿真
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摘要
根据型材拉弯设备结构和成形工况,将夹钳加载量等效为拉伸缸沿转臂的拉伸量和转臂的转角,并提出了一种基于增量控制的型材拉弯轨迹设计方法。通过沿轴线方向将型材目标形状划分成多个成形段,并求解出每个成形段对应的拉伸增量和转角增量,实现型材拉弯成形中加载量的独立分配与控制。以轨道车辆车顶乙形不锈钢弯梁作为研究对象,建立了一种基于连接器单元的型材拉弯有限元模型,并将计算得到的加载增量应用于工件成形效果仿真中,实现了拉弯轨迹的参数化调控。根据仿真结果中工件的形状误差与表面翘曲量分析了拉弯缺陷的成因,并对拉弯轨迹进行了针对性的修正,提升了工件成形效果。采用修正后的拉弯轨迹进行工件成形试验,仿真结果与试验结果相吻合。
According to the structure of the stretch bending equipment and the loading condition, the loading capacity of the jaw is equated to the tensile strength of the drawing cylinder and rotation angle of the turning arm, and a trajectory design method for profile stretch bending based on incremental control is proposed.By dividing the target shape into several forming sections and calculating the tensile strength increment and rotation angle increment, the independent distribution and control of the loading capacity are realized. The Z-shaped stainless steel curved roof beam is selected as the research object. The profile stretch bending FE simulation model composed of connector units is established. The calculated loading increment is applied in predicting the forming effects of the workpiece, which realizes the parameterized regulation of the loading trajectory. The forming defect analysis and pertinent modification are conducted according to the shape error and the surface warpage in the simulation results, which improve the forming effects. The modified trajectory is adopted in the forming test, and the simulation results meet well with the experimental results.
According to the structure of the stretch bending equipment and the loading condition, the loading capacity of the jaw is equated to the tensile strength of the drawing cylinder and rotation angle of the turning arm, and a trajectory design method for profile stretch bending based on incremental control is proposed.By dividing the target shape into several forming sections and calculating the tensile strength increment and rotation angle increment, the independent distribution and control of the loading capacity are realized. The Z-shaped stainless steel curved roof beam is selected as the research object. The profile stretch bending FE simulation model composed of connector units is established. The calculated loading increment is applied in predicting the forming effects of the workpiece, which realizes the parameterized regulation of the loading trajectory. The forming defect analysis and pertinent modification are conducted according to the shape error and the surface warpage in the simulation results, which improve the forming effects. The modified trajectory is adopted in the forming test, and the simulation results meet well with the experimental results.
引文
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[14]Sushanta G,Kashi N S.An experimental study on stress concentration around a hole under combined bending and stretching stress field[J].Procedia Technology,2016,23(1):2027.
[15]梁继业,邓钢,方斌.L型截面铝型材拉弯成形截面畸变缺陷控制研究[J].锻压技术,2016,41(12):4245.Liang Jiye,Deng Gang,Fang Bin.Section distortion control for Lsection aluminium profile part in the strecth-bending process[J].Foring and Stamping Tchnology,2016,41(12):4245.
[16]刘天娇,王永军,夏晓娇,等.型材拉弯数值模拟轨迹建模方法[J].锻压技术,2014,39(7):132137.Liu Tianjiao,Wang Yongjun,Xia Xiaojiao,et al.Trajectory modeling of extrusion stretch bending simulation[J].Forging and Stamping Technology,2014,39(7):132137.
[2]王胜满.用于地铁车辆的不锈钢型材拉弯成形缺陷[J].吉林大学学报:工学版,2013,43(6):15461550.Wang Sheng-man.Stretch bend forming defects of stainless steel profile of metro vechile[J].Journal of Jilin University(Engineering and Technology Edition),2013,43(6):15461550.
[3]谷诤巍,吕萌萌,李欣,等.数控拉弯工艺中型材变形量的影响因素[J].吉林大学学报:工学版,2016,46(4):11901196.Gu Zhengwei,Lyu Mengmeng,Li Xin,et al.Influence factors of profile deformation in NC stretch bending[J].Journal of Jilin University(Engineering and Technology Edition),2016,46(4):11901196.
[4]梁继才,李义,高嵩,等.型材多点柔性拉弯成形回弹预测[J].吉林大学学报:工学版,2017,47(1):185190.Liang Jicai,Li Yi,Gao Song,et al.Springback prediction for multipoint 3D stretch bending profile[J].Journal of Jilin University(Engineering and Technology Edition),2017,47(1):185190.
[5]Yu C L,Li X Q.Theoretical analysis on springback of Lsection extrusion in rotary stretch bending process[J].Transactions of Nonferrous Metals Society of China,2011,21(12):27052710.
[6]王永军,黄云华,王俊彪,等.数控转台拉弯机切点跟踪轨迹生成算法[J].机械工程学报,2005,41(10):123127.Wang Yongjun,Huang Yunhua,Wang Junbiao,et al.Algorithm of generating the tracking locus of the tangent point for NC rotary stretch-bending former[J].Chinese Journal of Mechanical Engineering,2005,41(10):123127.
[7]刘志军,金朝海,李东升,等.基于PSBPD的T型材拉弯夹钳加载轨迹设计及有限元模拟[J].塑性工程学报,2012,19(6):109113.Liu Zhijun,Jin Chaohai,Li Dongsheng,et al.PSBPDbased jaw trajectory design and numerical simulation for Tsection profile during stretchbending[J].Journal of Plasticity Engineering,2012,19(6):109113.
[8]Reinhard L.Coupling of bending and stretching deformation in vehicle members[J].Advances in Colloid and Interface Science,2014,208(1):1424.
[9]李小强,周贤宾,金朝海,等.基于有限元模拟的三维型材拉弯轨迹设计[J].航空学报,2009,30(3):544550.Li Xiaoqiang,Zhou Xianbin,Jin Chaohai,et al.Design of stretch bending trajectory based on finite element simulation for threedimensional profile parts[J].Acta Aeronautica et Astronautica Sinica,2009,30(3):544550.
[10]李小强,周贤宾,金朝海,等.型材拉弯数值模拟夹钳边界条件的一种等效模型[J].塑性工程学报,2009,16(1):6469.Li Xiaoqiang,Zhou Xianbin,Jin Chaohai,et al.An equivalent model of jaws boundary condition in numerical simulation of stretch bending for extrusions[J].Journal of Plasticity Engineering,2009,16(1):6469.
[11]张学广,刘纯国,张石磊,等.轴向非对称中空型材拉弯过渡区长度优化[J].哈尔滨工业大学学报,2015,47(10):8587.Zhang Xueguang,Liu Chunguo,Zhang Shilei,et al.Optimization of transition zone length in stretch bending of axially asymmetric hollow profiles[J].Journal of Harbin Institute of Technology,2015,47(10):8587.
[12]周苗苗,王红建,贺尔铭,等.复杂截面型材3D拉弯数值模拟建模技术研究[J].机械科学与技术,2012,31(6):888892.Zhou Miaomiao,Wang Hongjian,He Er-ming,et al.Investion of numerical modeling techniques of 3Dstretch bending for complex cross section[J].Mechanical Science and Technology for Aerospace Engineering,2012,31(6):888892.
[13]谷诤巍,张文学,吕萌萌,等.宽翼边U型截面不锈钢型材拉弯成形缺陷控制[J].吉林大学学报:工学版,2017,47(4):11651170.Gu Zhengwei,Zhang Wenxue,Lyu Mengmeng,et al.Stretch bending defect control of U-section stainless steel profile with wide flange[J].Journal of Jilin University(Engineering and Technology Edition),2017,47(4):11651170.
[14]Sushanta G,Kashi N S.An experimental study on stress concentration around a hole under combined bending and stretching stress field[J].Procedia Technology,2016,23(1):2027.
[15]梁继业,邓钢,方斌.L型截面铝型材拉弯成形截面畸变缺陷控制研究[J].锻压技术,2016,41(12):4245.Liang Jiye,Deng Gang,Fang Bin.Section distortion control for Lsection aluminium profile part in the strecth-bending process[J].Foring and Stamping Tchnology,2016,41(12):4245.
[16]刘天娇,王永军,夏晓娇,等.型材拉弯数值模拟轨迹建模方法[J].锻压技术,2014,39(7):132137.Liu Tianjiao,Wang Yongjun,Xia Xiaojiao,et al.Trajectory modeling of extrusion stretch bending simulation[J].Forging and Stamping Technology,2014,39(7):132137.