F18 B柱冷辊压成形工艺的研究
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摘要
冷辊压成形是金属板材和带材加工中的一个重要领域。由于冷辊压成形过程是几何、材料和接触边界等多重非线性的复杂变形,故影响成形过程的因素很多。虽然冷辊压型材已广泛应用于汽车、航空、轻工、机械制造等各个行业,但是,冷辊压成形工艺的确定主要依赖设计者的经验知识,因此,对冷辊压成形工艺的研究具有重要意义。
本文介绍了冷辊压成形过程以及冷辊压成形工艺。根据冷辊压成形工艺的设计原则,利用COPRA设计了F18 B柱进行滚花图的设计和辊型。采用COPRA软件中的变形模拟模块对设计的孔型和辊型进行模拟分析,同时利用DYNAFORM模拟软件对冷辊压成形过程进行了有限元模拟分析,通过分析成形过程、应力和应变,将成形中存在缺陷的道次进行了修改,得到合理的成形工艺。根据设计的F18 B柱冷辊压成形工艺制造了生产线,并对生产线进行了调试,对成形过程中存在的缺陷进行了分析,提出合理的解决方案。将实际调试中出现的问题与模拟分析做了比较,得出有限元模拟对冷辊压的成形过程起到一定的指导作用。
本文研究的目的是为了指导B柱类型材的生产。分析了冷辊压成形的原理和工艺,采用理论分析和有限元模拟相结合的方式,使得冷辊压成形工艺更加完善,将研究的成果应用于实际生产中,生产出合格产品。
Cold roll-forming is a significant field in forming of strip metal.Because the forming process of cold roll-forming is nonlinear deformation process that collect geometric distortion, material problem and contact boundaries problem, many factors influence the forming process. Though the piece of cold roll forming has been widely used in automotive, aerospace, light industry, machinery manufacturing industry, and etc, but the determination of the form- ing technology in cold roll-forming mainly dependent on engineer’s experience. Therefore, it is great importance to do research work on technology of cold roll forming.
The paper mainly introduce cold roll forming process and forming technol- ogy. Base on principle of cold roll forming, the flower diagram and roller designing of F18 B pillar are designed by software of COPRA. The groove pass and roller type are simulated by DTM in software of COPRA. And the forming process of cold roll forming is simulated by software of DYNAFORM. By analysising forming process, strain and stress, the defects in the forming are modified. The reasonable forming technology is gained. According to the design of forming technology of F18 B pillar, the production line is made. The defects in the forming are analysised, and the methods solving the defects are put forward. Compared the problems of practice and the problems of simulation, it can be concluded that the finite element simulation play a guiding role on the forming process of cold roll forming.
The purpose of the paper is to provide guidance to production of B pillar. The principle and technology of forming is analysised. and the forming process is simulated by finite element analysis. By combining with the forming theory and finate element analysis, the forming technology become better. The research achievement is applied in practice production, and the high-quality product is produced.
本文介绍了冷辊压成形过程以及冷辊压成形工艺。根据冷辊压成形工艺的设计原则,利用COPRA设计了F18 B柱进行滚花图的设计和辊型。采用COPRA软件中的变形模拟模块对设计的孔型和辊型进行模拟分析,同时利用DYNAFORM模拟软件对冷辊压成形过程进行了有限元模拟分析,通过分析成形过程、应力和应变,将成形中存在缺陷的道次进行了修改,得到合理的成形工艺。根据设计的F18 B柱冷辊压成形工艺制造了生产线,并对生产线进行了调试,对成形过程中存在的缺陷进行了分析,提出合理的解决方案。将实际调试中出现的问题与模拟分析做了比较,得出有限元模拟对冷辊压的成形过程起到一定的指导作用。
本文研究的目的是为了指导B柱类型材的生产。分析了冷辊压成形的原理和工艺,采用理论分析和有限元模拟相结合的方式,使得冷辊压成形工艺更加完善,将研究的成果应用于实际生产中,生产出合格产品。
Cold roll-forming is a significant field in forming of strip metal.Because the forming process of cold roll-forming is nonlinear deformation process that collect geometric distortion, material problem and contact boundaries problem, many factors influence the forming process. Though the piece of cold roll forming has been widely used in automotive, aerospace, light industry, machinery manufacturing industry, and etc, but the determination of the form- ing technology in cold roll-forming mainly dependent on engineer’s experience. Therefore, it is great importance to do research work on technology of cold roll forming.
The paper mainly introduce cold roll forming process and forming technol- ogy. Base on principle of cold roll forming, the flower diagram and roller designing of F18 B pillar are designed by software of COPRA. The groove pass and roller type are simulated by DTM in software of COPRA. And the forming process of cold roll forming is simulated by software of DYNAFORM. By analysising forming process, strain and stress, the defects in the forming are modified. The reasonable forming technology is gained. According to the design of forming technology of F18 B pillar, the production line is made. The defects in the forming are analysised, and the methods solving the defects are put forward. Compared the problems of practice and the problems of simulation, it can be concluded that the finite element simulation play a guiding role on the forming process of cold roll forming.
The purpose of the paper is to provide guidance to production of B pillar. The principle and technology of forming is analysised. and the forming process is simulated by finite element analysis. By combining with the forming theory and finate element analysis, the forming technology become better. The research achievement is applied in practice production, and the high-quality product is produced.
引文
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2中国钢协冷弯型钢CAD/CAM技术中心.http://www.rollforming.com.cn/RF1.HTM
3杨毅勇.高强度汽车纵梁冷弯成形工艺及模具的柔性化研制.锻压装备与制造技术,2010,03:42-44
4徐娟.冷弯辊型设计过程知识表示与推送.机械设计与研究,2008,02:23-27
5刘江林.有限元在冷弯型钢中的应用.精密成形工程,2011,02:2-5
6刘洋,谢伟平,蔡玉春.冷弯型钢发展与应用综述.钢结构,2004,6,(19):36-37
7姚行友.冷弯薄壁型钢构件畸变屈服研究现状.结构工程师,2010,05:55-58
8张欣,李国栋,李凤莲等.对我国型材生产的展望.山东冶金,2007,29:17-18
9乔自平.复杂断面冷弯型钢在线切断模具设计.锻压技术,2007,05:8-12
10丁国良.中国冷弯行业发展现状及前景.钢结构,2008,23(103):75-76
11李昕然.冷弯型钢在线剪切数值模拟.锻压装备与制造技术,2009,02:15-18
12 [美]于炜文著.冷成形钢结构设计.董军,夏冰青译.原文第三版.北京:中国水利水电出版社,2002:1-34
13曲鹏远.冷弯型钢的应用与研究现状.科技风,2008:11,22-26
14崔高建,吕相艳,迟正洪.冷弯型钢成型技术发展现状.机械制造,2005,43(494):41-44
15Г.Я.古恩著,金属塑性加工理论基础.赵志业,王同泽译.北京:冶金工业出版社,1989:54-90
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17张祎.不锈钢波纹板冷弯成形有限元模拟研究,2011,01:13-15
18 K.Nakajima,Miznutaniw.Development of New Vertical Roll Forming Process for ERW Pipe.Nippon Steel T echnical Report,1980,(15):127-144
19 T. R.Walker,R.J.Pick.Approximation of the Axial Strains Developed During the Roll Forming of Pipe.Journal of Mater Processing Technology,1990,22:29-44
20胡中.塑性有限元模拟技术的最新进展.塑性工程学报,1994,1(3):3-12
21木内学.スタンド间の变形曲面形状と附加的ひずみ成分の分布(1).塑性と加工,1971,12(120):20-29
22小野田义富,川井彰.电缝管のWべンド成形およびUべンド成形における素板の变形特性の有限要素シミユレシヨン.塑性と加工,1993,34(395):1358-1363
23小野田义富,长町拓夫等.ェクストロ-ルフォ-ミソケにする正方形角钢管の断面形状に及ぽすェクスハソド方式の角化予成形の影响.塑性と加工,1995,36(412):487-492
24小野田义富,长町拓夫等.正方形角钢管のェクストロ-ルフォ-ミソグにすける增肉举动の有限要素ツミュレ-ツョソ.塑性と加工,1995:36(409):149-154
25小野田义富,长町拓夫等.ェクストロ-ルフォ-ミソグにすり溶接丸钢管から角钢管再成形する场合の素钢管押レ込み荷重おすび成型荷重.塑性と加工,1993:34(388):526-531
26小野田义富,河野光雄等.ハット型钢のNO.1ロ-ルにおける素板の变形举动の解析.平成6年度塑性加工春季讲演会,1994,5:26-28
27 S.M.Panton, J.L.Duncan. Longitudinal and Shear Development in Cold Roll Forming. Journal of Mater Processing Technology,1996,60:219-224
28 G.Nefuss, P.Gilormini. A Simplified Method for the Simulation of Cold-Roll forming. Int. J .Mech.Sci,1993, 35(10):867-878
29 G .Nefuss, L.Proslier.A Simulation of Cold-roll Forming for Elastoplastic Material.In- t.J .Mech.Sci,1998,40(1):15-25
30 Nitin Duggal, Taylan Altan.Computer Aided Simulation of Cold Roll Forming Comp- ter Program for Simple Section Profiles. Journal of Mater Processing Technology, 1996,59:41-48
31 M.Brunet, B.Lay.Computer Aided Design of Roll-forming of Channel Sections. Jour- nal of Mater Processing Technology,1996,60:209-214
32 R.S.Senanayake, I.M.Cole.The Application of Computational and Experimental Tech- iques to Metal Deformetion Cold Roll Forming.Journal of Mater Processing Technol- gy,1994,45:155-160
33蔡松庆,赖明道.直缝焊管成形的有限元素分析.力学与实践(增刊),1986:35-41
34 Zhiwu Han,Cai Liu,Weiping Lu.Computer Simulation of A Non-Symmetrical-Section Steel Forming Process By The Spline Finite Strip Method Based on The U.L.Method. Jourmal of Materials Processing Technology,2000,103:343-346
35 C.Liu,Y.Zhou,W.Lu.Numerical Mulation of RollForming By The B-Spline Strip Met- thod.Jourmal of Materials Processing Technology,1996,60:215-218
36徐树成.辊弯成形的三维大变形有限元模拟.[燕山大学博士研究生论文].1997:2-8
37徐树成,王先进,刘才.弹塑性大变形有限元分析槽钢成型过程的位移场和速度场.塑性工程学报,1999,6(3):69-73
38韩志武.基于大变形有限条法的冷弯成形计算机模拟与专家系统技术的研究.[燕山大学工学博士学位论文].1998:1-9
39曾国,来民新,于忠奇等.多道次辊弯成形数值模拟技术.上海:上海交通大学学报,2007,41(10):1598-1662
40邹仲平,刘化民,孙正旭.不锈钢波纹板冷弯成形规律研究.制造,2009,17:143-144
41王飞龙,张代明,张署红.冷弯型钢成形回弹过程有限元模拟研究.昆明:昆明理工大学学报,2004,29(6):40-42
42郑军兴,张署红.板料厚度对冷弯成形及回弹影响的模拟研究.轧钢,2007,2:22-24
43郑军兴.成形道次对回弹影响的模拟研究.锻压技术,2008,6:29-31
44史永陵,刘继英.先进高强度钢辊弯成型工艺仿真研究.焊管,2007,20(02):29-62
45卜高乐.变截面冷弯成形的FEA仿真研究.[北方工业大学硕士学位论文].2007:1-3
46幺志刚.冷弯型钢CAD网络化技术的研究.[燕山大学工学硕士学位论文].2004:8-9
47王春新,刘继英.冷弯成型过程仿真技术的发展.北方工业大学报,2004,16(1):46-50
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49方圣恩.冷弯薄壁槽钢腹板压屈及弯压有限元分析和设计.[福州大学硕士学位论文].2004:1-3
50 Sukmoo Hong, Seungyoon Lee, Naksoo Kim. A Parametric study on forming length in roll forming. Journal of Materials Processing Technology,2001,113:774-778
51 T. Katayama, Y. Hayakawa, M. Hakotani & M. Shinohara. Application of roll forming to SMC forming. Composite Structures,1997,38,(1-4):517-524
52 Y. Kasuga. Change in shape of a cold formed and annealed stainless steel sheet and joining with use of this change. Journal of Materials Processing Technology, 1996, 60: 233-238
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55刘继英.冷弯成型CAD/CAM的一体化技术.北方工业大学学报,1996,8(3):18-20
56 Albert Sedlmaler, Vallry著.应用有限元方法预示焊管成型后续工序的加工特性.李凯,史永陵译.中国冷弯型钢协会技术服务中心,2010:2-7
57张晨光.面向对象方法在冷弯成形CAD系统中的应用研究.[燕山大学工学硕士学位论文].1999:1-4
58刘化民.不锈钢波纹顶板冷弯成型过程模拟研究.锻压装备与制造技术,2008:70-72
2中国钢协冷弯型钢CAD/CAM技术中心.http://www.rollforming.com.cn/RF1.HTM
3杨毅勇.高强度汽车纵梁冷弯成形工艺及模具的柔性化研制.锻压装备与制造技术,2010,03:42-44
4徐娟.冷弯辊型设计过程知识表示与推送.机械设计与研究,2008,02:23-27
5刘江林.有限元在冷弯型钢中的应用.精密成形工程,2011,02:2-5
6刘洋,谢伟平,蔡玉春.冷弯型钢发展与应用综述.钢结构,2004,6,(19):36-37
7姚行友.冷弯薄壁型钢构件畸变屈服研究现状.结构工程师,2010,05:55-58
8张欣,李国栋,李凤莲等.对我国型材生产的展望.山东冶金,2007,29:17-18
9乔自平.复杂断面冷弯型钢在线切断模具设计.锻压技术,2007,05:8-12
10丁国良.中国冷弯行业发展现状及前景.钢结构,2008,23(103):75-76
11李昕然.冷弯型钢在线剪切数值模拟.锻压装备与制造技术,2009,02:15-18
12 [美]于炜文著.冷成形钢结构设计.董军,夏冰青译.原文第三版.北京:中国水利水电出版社,2002:1-34
13曲鹏远.冷弯型钢的应用与研究现状.科技风,2008:11,22-26
14崔高建,吕相艳,迟正洪.冷弯型钢成型技术发展现状.机械制造,2005,43(494):41-44
15Г.Я.古恩著,金属塑性加工理论基础.赵志业,王同泽译.北京:冶金工业出版社,1989:54-90
16В.И.达维多夫,М.П.马科萨柯夫著.薄壁冷弯型钢生产.穆东生译.第2版.北京:中国工业出版社,1962:10-229
17张祎.不锈钢波纹板冷弯成形有限元模拟研究,2011,01:13-15
18 K.Nakajima,Miznutaniw.Development of New Vertical Roll Forming Process for ERW Pipe.Nippon Steel T echnical Report,1980,(15):127-144
19 T. R.Walker,R.J.Pick.Approximation of the Axial Strains Developed During the Roll Forming of Pipe.Journal of Mater Processing Technology,1990,22:29-44
20胡中.塑性有限元模拟技术的最新进展.塑性工程学报,1994,1(3):3-12
21木内学.スタンド间の变形曲面形状と附加的ひずみ成分の分布(1).塑性と加工,1971,12(120):20-29
22小野田义富,川井彰.电缝管のWべンド成形およびUべンド成形における素板の变形特性の有限要素シミユレシヨン.塑性と加工,1993,34(395):1358-1363
23小野田义富,长町拓夫等.ェクストロ-ルフォ-ミソケにする正方形角钢管の断面形状に及ぽすェクスハソド方式の角化予成形の影响.塑性と加工,1995,36(412):487-492
24小野田义富,长町拓夫等.正方形角钢管のェクストロ-ルフォ-ミソグにすける增肉举动の有限要素ツミュレ-ツョソ.塑性と加工,1995:36(409):149-154
25小野田义富,长町拓夫等.ェクストロ-ルフォ-ミソグにすり溶接丸钢管から角钢管再成形する场合の素钢管押レ込み荷重おすび成型荷重.塑性と加工,1993:34(388):526-531
26小野田义富,河野光雄等.ハット型钢のNO.1ロ-ルにおける素板の变形举动の解析.平成6年度塑性加工春季讲演会,1994,5:26-28
27 S.M.Panton, J.L.Duncan. Longitudinal and Shear Development in Cold Roll Forming. Journal of Mater Processing Technology,1996,60:219-224
28 G.Nefuss, P.Gilormini. A Simplified Method for the Simulation of Cold-Roll forming. Int. J .Mech.Sci,1993, 35(10):867-878
29 G .Nefuss, L.Proslier.A Simulation of Cold-roll Forming for Elastoplastic Material.In- t.J .Mech.Sci,1998,40(1):15-25
30 Nitin Duggal, Taylan Altan.Computer Aided Simulation of Cold Roll Forming Comp- ter Program for Simple Section Profiles. Journal of Mater Processing Technology, 1996,59:41-48
31 M.Brunet, B.Lay.Computer Aided Design of Roll-forming of Channel Sections. Jour- nal of Mater Processing Technology,1996,60:209-214
32 R.S.Senanayake, I.M.Cole.The Application of Computational and Experimental Tech- iques to Metal Deformetion Cold Roll Forming.Journal of Mater Processing Technol- gy,1994,45:155-160
33蔡松庆,赖明道.直缝焊管成形的有限元素分析.力学与实践(增刊),1986:35-41
34 Zhiwu Han,Cai Liu,Weiping Lu.Computer Simulation of A Non-Symmetrical-Section Steel Forming Process By The Spline Finite Strip Method Based on The U.L.Method. Jourmal of Materials Processing Technology,2000,103:343-346
35 C.Liu,Y.Zhou,W.Lu.Numerical Mulation of RollForming By The B-Spline Strip Met- thod.Jourmal of Materials Processing Technology,1996,60:215-218
36徐树成.辊弯成形的三维大变形有限元模拟.[燕山大学博士研究生论文].1997:2-8
37徐树成,王先进,刘才.弹塑性大变形有限元分析槽钢成型过程的位移场和速度场.塑性工程学报,1999,6(3):69-73
38韩志武.基于大变形有限条法的冷弯成形计算机模拟与专家系统技术的研究.[燕山大学工学博士学位论文].1998:1-9
39曾国,来民新,于忠奇等.多道次辊弯成形数值模拟技术.上海:上海交通大学学报,2007,41(10):1598-1662
40邹仲平,刘化民,孙正旭.不锈钢波纹板冷弯成形规律研究.制造,2009,17:143-144
41王飞龙,张代明,张署红.冷弯型钢成形回弹过程有限元模拟研究.昆明:昆明理工大学学报,2004,29(6):40-42
42郑军兴,张署红.板料厚度对冷弯成形及回弹影响的模拟研究.轧钢,2007,2:22-24
43郑军兴.成形道次对回弹影响的模拟研究.锻压技术,2008,6:29-31
44史永陵,刘继英.先进高强度钢辊弯成型工艺仿真研究.焊管,2007,20(02):29-62
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