不锈钢波纹板辊型设计及冷弯成形规律研究
摘要
冷弯型钢产品具有断面合理、强度高、重量轻及金属利用率高等优点,是一种经济断面型钢。尽管冷弯成形产品的生产和应用已有百余年的历史,产量也达到了一定的水平,但由于其本身所具有的特点和规律尚未完全被人们所认识和掌握,其仍然被称为是一门“未掌握的艺术”。随着市场对高品质多品种冷弯产品需求的不断提高,试制时间长,精度差的传统设计和加工方式已经远远不能满足用户的要求,采用计算机对冷弯型钢进行辊型和孔型设计及冷弯成形过程分析(CAE)技术已经成为冷弯型钢发展的趋势。
本文进行了不锈钢波纹板CARD系统的主菜单界面及各级子菜单界面的设计工作,并介绍了与菜单相关的各个窗体的功能及操作顺序和方法;然后利用Marc软件对不锈钢波纹板的冷弯成形过程进行了三维弹塑性有限元模拟,建立了冷弯成形的有限元模型,得到了不同成形阶段金属板材的等效应力、横向应变及纵向应变变化和分布规律,为生产设计工作提供了参考;并在此模拟分析研究的基础上,进行了不锈钢波纹板的辊型和孔型设计,探索了冷弯成形在不锈钢波纹板中的应用;通过工艺试验和生产线调试,成功地研制出不锈钢冷弯波纹板,为其广泛应用奠定了基础。
The cold-rolled forming section is economic sectional material and has been used in auto,aviation, architecture etc due to the section is homogeneous, products are high quality, energy consumption is low and economic performance is affluent. Though the production and application history of cold-rolled forming section products has last out centenary and yield has reached to definite level, cold bend forming go by the name of“not master art”because itself characteristic and rule has not been comprehended and mastered.
The cold bending forming process is a kind of the plate distortion which occurs under the normal temperature and the low speed, and the rigidity of the roller is bigger than the plate by far, , therefore the cold bending forming process is very difficult, the formed rule grasps with difficulty. At present, the domestic and foreign scholars had not proposed regarding this one very perfect precise analysis method, in the production pass and the roller design as well as the technological design were mainly still decided by the experience knowledge. Therefore, using Visual Basic 6.0 has developed CARD system of the stainless steel corrugated plate; using the Marc software Carries on the three dimensional elastoplasticity finite element simulation to cold bending forming process of the stainless steel corrugated plate, analyzes the analysis different forming stage metal plate equivalent stress, the lateral strain,the longitudinal strain change and the distribution rule, thus grasps the change rule of the metal flow, these work not can only deepen to the cold bending forming theory research, and has the great significance to the actual production and the design optimization. This article primary coverage and the conclusion are as follows:
1. Design of CARD system's contact surface of stainless steel corrugated plate Using Visual Basic 6.0 has carried on CARD system's contact surface the corrugated sheet CARD system's main menu contact surface and all levels of child menu contact surface project work of stainless steel corrugated plate, introduced the menu related each window function and the operation sequence and the method.
2. The research of cold bending forming of Stainless steel corrugated plate
Using basic principle of the finite element simulation and simplification analysis method of the cold bending forming, finite element model of the corrugated plate has been established, and the computation model was simplified according to the symmetrical body characteristic, the effective boundary condition and the geometry restraint has been exerted, nipped into the process was simplified, the plate advance's link speed and the previous bottom roll's rotational speed had been determined, the contact way of the rigid body roller and the deformable body plate has been established, cold bending forming process of the beat resonance plate has been carried on the numerical simulation, was obtained the different formed stage equivalent Mises stress and the strain change situation in the cold bending forming process.the result as follows:
(1) Equivalent Mises stress is increases along with the pass, but the maximum value of the sixth compares with the fifth has reduces as a result of residual stress's release; the equivalent Mises strain is quite fierce in the bending angle spot and the curving neighbor spot of the middle of corrugated plate, but stress distribution is quite even and the change is gentle in the base spot; More approaches to the roller spot, the stress maximum value was much bigger than in the between of the roller, this is the primary cause of easy to have the flaw nearby the roller;
(2) According to the strain change rule and the characteristic obtains: the plate is by the transverse curl distortion and the longitudinal elasticity stretch elongation joint action result, but distorts mainly concentrates in crosswise, the bending strain is not strongly in bending angle spot, but strains is uniform distribution in bending angle spot nearby section of distance internal; In exit of the roller, the bending strain concentrates gradually in the bending angle spot, and has the obvious peak value, and in crosswise, the bending strain increases along with the formed angle, the lateral deformation performance for plate curving main distortion. Therefore when designing the pass, the lateral deformation rational distribution question is mainly considered, thus better guarantee product quality.
3. Roller design and engineer testing research of stainless steel corrugated plate
First carries on the analysis computation to the stainless steel corrugated plate, the materials width, the formed pass, and cold bending forming parameter had been determined, then the roller flower chart was designed, then the roller chart and the roller piece was designed according to the roller flower chart. Then uniting the numerical simulation result, the stainless steel corrugated plate has been conducted engineer testing research, the technique of production and the equipment first briefly introduced, then this set of cold bending forming unit's debugging process have been carried on, the question as well as solution which in the experiment meets has analyzed. Finally, the qualified stainless steel corrugated plate is developed successfully.
本文进行了不锈钢波纹板CARD系统的主菜单界面及各级子菜单界面的设计工作,并介绍了与菜单相关的各个窗体的功能及操作顺序和方法;然后利用Marc软件对不锈钢波纹板的冷弯成形过程进行了三维弹塑性有限元模拟,建立了冷弯成形的有限元模型,得到了不同成形阶段金属板材的等效应力、横向应变及纵向应变变化和分布规律,为生产设计工作提供了参考;并在此模拟分析研究的基础上,进行了不锈钢波纹板的辊型和孔型设计,探索了冷弯成形在不锈钢波纹板中的应用;通过工艺试验和生产线调试,成功地研制出不锈钢冷弯波纹板,为其广泛应用奠定了基础。
The cold-rolled forming section is economic sectional material and has been used in auto,aviation, architecture etc due to the section is homogeneous, products are high quality, energy consumption is low and economic performance is affluent. Though the production and application history of cold-rolled forming section products has last out centenary and yield has reached to definite level, cold bend forming go by the name of“not master art”because itself characteristic and rule has not been comprehended and mastered.
The cold bending forming process is a kind of the plate distortion which occurs under the normal temperature and the low speed, and the rigidity of the roller is bigger than the plate by far, , therefore the cold bending forming process is very difficult, the formed rule grasps with difficulty. At present, the domestic and foreign scholars had not proposed regarding this one very perfect precise analysis method, in the production pass and the roller design as well as the technological design were mainly still decided by the experience knowledge. Therefore, using Visual Basic 6.0 has developed CARD system of the stainless steel corrugated plate; using the Marc software Carries on the three dimensional elastoplasticity finite element simulation to cold bending forming process of the stainless steel corrugated plate, analyzes the analysis different forming stage metal plate equivalent stress, the lateral strain,the longitudinal strain change and the distribution rule, thus grasps the change rule of the metal flow, these work not can only deepen to the cold bending forming theory research, and has the great significance to the actual production and the design optimization. This article primary coverage and the conclusion are as follows:
1. Design of CARD system's contact surface of stainless steel corrugated plate Using Visual Basic 6.0 has carried on CARD system's contact surface the corrugated sheet CARD system's main menu contact surface and all levels of child menu contact surface project work of stainless steel corrugated plate, introduced the menu related each window function and the operation sequence and the method.
2. The research of cold bending forming of Stainless steel corrugated plate
Using basic principle of the finite element simulation and simplification analysis method of the cold bending forming, finite element model of the corrugated plate has been established, and the computation model was simplified according to the symmetrical body characteristic, the effective boundary condition and the geometry restraint has been exerted, nipped into the process was simplified, the plate advance's link speed and the previous bottom roll's rotational speed had been determined, the contact way of the rigid body roller and the deformable body plate has been established, cold bending forming process of the beat resonance plate has been carried on the numerical simulation, was obtained the different formed stage equivalent Mises stress and the strain change situation in the cold bending forming process.the result as follows:
(1) Equivalent Mises stress is increases along with the pass, but the maximum value of the sixth compares with the fifth has reduces as a result of residual stress's release; the equivalent Mises strain is quite fierce in the bending angle spot and the curving neighbor spot of the middle of corrugated plate, but stress distribution is quite even and the change is gentle in the base spot; More approaches to the roller spot, the stress maximum value was much bigger than in the between of the roller, this is the primary cause of easy to have the flaw nearby the roller;
(2) According to the strain change rule and the characteristic obtains: the plate is by the transverse curl distortion and the longitudinal elasticity stretch elongation joint action result, but distorts mainly concentrates in crosswise, the bending strain is not strongly in bending angle spot, but strains is uniform distribution in bending angle spot nearby section of distance internal; In exit of the roller, the bending strain concentrates gradually in the bending angle spot, and has the obvious peak value, and in crosswise, the bending strain increases along with the formed angle, the lateral deformation performance for plate curving main distortion. Therefore when designing the pass, the lateral deformation rational distribution question is mainly considered, thus better guarantee product quality.
3. Roller design and engineer testing research of stainless steel corrugated plate
First carries on the analysis computation to the stainless steel corrugated plate, the materials width, the formed pass, and cold bending forming parameter had been determined, then the roller flower chart was designed, then the roller chart and the roller piece was designed according to the roller flower chart. Then uniting the numerical simulation result, the stainless steel corrugated plate has been conducted engineer testing research, the technique of production and the equipment first briefly introduced, then this set of cold bending forming unit's debugging process have been carried on, the question as well as solution which in the experiment meets has analyzed. Finally, the qualified stainless steel corrugated plate is developed successfully.
引文
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[4] R. J. Dyke, S. J. Mander, D. Bhattacharyya.Roll Forming Continuous Fiber- Reinforced Thermoplastic Sheets: Expereimental Analysis.The Second Australasis- an Conference on Materials, 2000, 31:1395-1407
[5] 张利鹏,周宏宇.冷弯型钢特点及其生产发展.锻压装备与制造技术,2005 (2):26-28
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[12] 韩志武,任露泉,刘才,陆卫平.冷弯成形数值模拟与孔型 CAD 集成系统.钢铁,2001,36(7):31-33
[13] New Features Guide.U. S. A. MSC. Software Corporation, 2006:199-215
[14] Training Guide.U. S. A. MSC. Software Corporation, 2006:89-117
[15] Use’s Guide.U. S .A. MSC. Software Corporation, 2006:85-129
[16] Element Library.U. S. A. MSC. Software Corporation, 2006:130-136
[17] Demonstration Problems.U. S .A .MSC. Software Corporation, 2006:409-1673
[18] 陈火红,于军泉,席源山.MSC.Marc/Mentat 2003 基础与应用实例.北京:科学出版社,2004
[19] 张卫华.中文 Visual Basic 6.0 编程技术.北京:北京航空航天大学出版社, 1999:339-358
[20] 清源计算机工作室.Visual Basic 6.0 开发宝典.北京:机械工业出版社,1999:125-130
[21] Microsoft Visual Studio 6.0 Development System.MSDN
[22] 宋伟,吴建国.中文 visual Basic 高级编程.北京:清华大学出版社,1999:230-235
[23] 张晋西.Visual Basic 与 AutoCAD 开发技术.北京:清华大学出版社,2002:139-143
[24] 张树兵.Visual Basic 6.0 入门与提高.清华大学出版社,1999
[25] H.C.Kwon, Y.T.Im.Interactive computer-aided-design system for roll pass and profile design in bar rolling.Journal of Materials Processing Technology,2002,123:399-405
[26] 吴振强.冷弯成形有限元分析及实验研究.昆明理工大学硕士学位论文,2004
[27] Sukmoo Hong,seungyoon Lee,et al. A parametric study on forming length in roll forming.J.Mater.Process. Technol,2001(113):774-778
[28] Nitin, Duggal, Taylan A. ltan.Computer Aided Simulation of Cold Roll Forming, Computer Program for Simple Section Profiles, J Mater Process Technol,1996, 59:41-48
[29] 韩志武,刘才等.工艺参数对简单断面型钢辊弯成形过程的影响.金属学报,2002(3):331-333
[30] 沈晓辉.实用冷弯型钢辊型设计专家系统的研究与开发.北京科技大学学位论文,2002:75-76
[31] H. Ona.Roll Adjustment and Computer Aided Design in Cold Roll Forming.Taku- shoku University, Tokyo, 2003
[32] H.Ona, H. Watari, T. Nakako. Production method on pipe of thin-spring steel sheet, J. Mater. Process. Technol,2001,(115): 92–96.
[33] Alsamhana, P. Hartelyb, I. Pillingerb.The computer simulation of cold-roll-forming using FE methods applied real time remeshing techniques,Journal of Materials Processing Technol,2003,(142):102–111
[34] A.Alsamhan.The development of finite-element models and remeshing techniques in the computer simulation of cold roll forming, Ph.D. Thesis, School of Manufacturing and Mechanical Engineering, The University of Birmingham, 1999
[35] S. M, Duncan. J. L, Zhu. S. D.Longitudinal and Shear Stain Development in Cold Roll Forming, J Mater Process Tech, 1996, 60:219-224
[36] 张宝生.高度非线性有限元分析软件 Marc 及在接触分析中的应用.应用科技,2001, 28(12) :36-39
[37] Farzin M, Salmani Tehrani M, Shameli E.Determination of buckling limit of strain in cold roll forming by the finite element analysis. J Mater Process Technol,2002
[38] Salmani Tehrani M, Hartley P, Moslemi Naeini H, Farzin M.Localised bending defect in circular tube rollforming. Proceedings of the eighth ESAFORM conference on material forming, Cluj,Romania,2005
[39] Jiying Liu,Zhengqing Ai,Chun Wang,Yanbin Xia.New Achievements in Cold Roll Forming Process2004
[40] Narasinhan K, Nandedkar M, Finite Element Modeling of plane Forming Limit Strains under Constant and Changing Strain Paths, J K Lee, NUMISHET'96, USA,1996:280
[41] Telue YK. Behaviour and design of plasterboard lined cold-formed steel stud wall systems under axial compression. PhD Thesis, School of Civil Engineering, Queensland University of Technoloogy, Brisbane, Australia, 2001
[42] S. Pimpasakdi, F.G. Albermani, S. Kitipornchai.Interactive analysis and design of cold formed steel cladding system.Journal of Constructional Steel Research,2004,60:1409–1423
[43] Cold-formed steel design manual. Washington, DC: American Iron and Steel Institute, 1997
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