高强度钢板冲压件回弹的研究
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摘要
回弹是板料成形中的三种主要缺陷之一,也是其中最难控制的。回弹的存在直接影响到冲压件的形状、尺寸、精度和表面质量。特别是近年来高强度钢板在汽车车身制造中的大量应用,使得回弹问题尤为突出。高强度钢的机械性能和普通低碳钢有很大差异,钢板高强度化易引起塑性下降,成形性变差,而屈服强度的提高则引起面畸变和显著的回弹效应,增加形状不稳定性。因此,高强度钢冲压成形中的回弹是工业生产中的一个实际问题,也是学术界关注的热点。
首先,在参考大量国内外技术资料的基础上,阐述了板料成形数值模拟理论中的关键技术。针对目前的研究现状,指出在分析板料成形问题时应采用大变形弹塑性有限元法,使用有限元模拟软件Dynaform,并结合弹塑性有限元方法对冲压件的回弹规律进行了研究。
其次,分析了板料成形中产生回弹的原因,阐述了在回弹研究中所采用的建模方法和计算方法,同时分析了影响回弹预测的因素。
然后,建立了曲面扁壳件的力学模型及有限元模型,分析了压边力、摩擦系数、板料厚度、拉深深度以及拉深筋对回弹的影响规律,介绍了回弹控制的一些方法,并利用模拟所得的结论和模具型面补偿方法对回弹进行了控制,研究结论对其它冲压件生产的回弹控制起到指导和参考意义。
最后,通过正交实验方法分析各因素对回弹的影响程度,进而确定相关参数的合理数值,并通过实验加以验证。
Springback is one of three main defects and also the most difficult to control. The existence of springback will affect the shape, size, precision and surface quality of the part. Springback problem becomes more impressing, especially with the wide use of the high strength sheet steel in the automobile body manufacturing. There are great differences between high strength steel and low carbon steel. High strength results in decreasing plasticity, poor formability, whereas improving yield strength will lead to surface aberration, obvious springback and unstable shape. So springback problem is both a problem that exists in the industry and a hotspot that the academia has paid attention to for a long time.
Firstly, illustrates the key technology of the numerical simulation theory of blanks forming in details based on a great deal of overseas and domestic technical information.
Secondly, it analyzes the reason of springback during the process of the blanks forming and introduces the way of constructing models and computation methods in the research of springback. It also analyzes the factors which affect springback forecast.
Thirdly, the mechanics and finite element model of curvy flat hull part is founded and blank holder force, friction coefficient, the effect of thickness, and drawbeads on springback is analyzed. it introduces some ways to control the springback. And the simulation results and die surface compensation methods are used to control the springback. Then it obtains a good result in controlling the springback of other parts by using the research conclusion.
Last but not the least, orthogonal experimental methods are used to study the impact of the various factors on springback, and then the reasonable value parameters are determined and verified by experiment.
首先,在参考大量国内外技术资料的基础上,阐述了板料成形数值模拟理论中的关键技术。针对目前的研究现状,指出在分析板料成形问题时应采用大变形弹塑性有限元法,使用有限元模拟软件Dynaform,并结合弹塑性有限元方法对冲压件的回弹规律进行了研究。
其次,分析了板料成形中产生回弹的原因,阐述了在回弹研究中所采用的建模方法和计算方法,同时分析了影响回弹预测的因素。
然后,建立了曲面扁壳件的力学模型及有限元模型,分析了压边力、摩擦系数、板料厚度、拉深深度以及拉深筋对回弹的影响规律,介绍了回弹控制的一些方法,并利用模拟所得的结论和模具型面补偿方法对回弹进行了控制,研究结论对其它冲压件生产的回弹控制起到指导和参考意义。
最后,通过正交实验方法分析各因素对回弹的影响程度,进而确定相关参数的合理数值,并通过实验加以验证。
Springback is one of three main defects and also the most difficult to control. The existence of springback will affect the shape, size, precision and surface quality of the part. Springback problem becomes more impressing, especially with the wide use of the high strength sheet steel in the automobile body manufacturing. There are great differences between high strength steel and low carbon steel. High strength results in decreasing plasticity, poor formability, whereas improving yield strength will lead to surface aberration, obvious springback and unstable shape. So springback problem is both a problem that exists in the industry and a hotspot that the academia has paid attention to for a long time.
Firstly, illustrates the key technology of the numerical simulation theory of blanks forming in details based on a great deal of overseas and domestic technical information.
Secondly, it analyzes the reason of springback during the process of the blanks forming and introduces the way of constructing models and computation methods in the research of springback. It also analyzes the factors which affect springback forecast.
Thirdly, the mechanics and finite element model of curvy flat hull part is founded and blank holder force, friction coefficient, the effect of thickness, and drawbeads on springback is analyzed. it introduces some ways to control the springback. And the simulation results and die surface compensation methods are used to control the springback. Then it obtains a good result in controlling the springback of other parts by using the research conclusion.
Last but not the least, orthogonal experimental methods are used to study the impact of the various factors on springback, and then the reasonable value parameters are determined and verified by experiment.
引文
1王新华.汽车冲压技术.北京:北京理工大学出版社,1999:1～5
2钟志华,李光耀.薄板冲压成形过程的计算机仿真与应用.北京理工大出版社,1998:5～8
3丰慧珍.先进高强度钢板冲压成形回弹的预测与控制.重庆:重庆大学硕士学文论文.2007:1～5
4 Makinouchi A,Kawka M.Process Simulation in Sheet Metal orming[J].Journal of Materials Processing Technology.1994,46:291～307
5 D.Zhoua, R.Wagonera H.Development and application of sheet-forming simulation[J].Journal of Materials Processing Technology.1995,(50):1～16
6余同希,张亮炽.塑性弯曲理论及其应用.北京:科学出版社,1992:45～86,181～187
7 H.Z.Dong. Z.Q.Lin.Investigation of sheet metal forming by numerical simulation and xperiment.J.Mater.Process.Technol.2000,(103):404～410
8官英平,赵军.板材V形自由弯曲智能化控制技术.研究与应用.2005,(12):1
9 Taylor L.Cao J.Karafillis A P,et al.Numerical simulations of sheet-metal forming[J].Journal of Materials Processing Technology.1995,(50): 168～179
10王孝培.实用冲压技术手册.北京:机械工业出版社,2001:13～15
11 Hill.R.塑性数学理论.王仁等译.北京:科学出版社,1966:312～319
12 Leu.D.K.A simplified approach for evaluating bendability and springback in plastic bending of anisotropic sheet metals [J].Journal of Materials Processing Technology.1997,(66):9～17
13 M.L.Wenner.On Work Hardening and Springback in Plane Strain Draw Forming [J].Applied Metal Working.1983,2(4):277
14 K.J.Weinmann,A.H.Rossenberger,etc.The Bauschinger effect of sheet metal under cyclic reverse pure bending [J].Annals of CIRP.1998,37(1):289
15 C.C.Chu.The effect of restraining force on springback [J].International Journal of Solid and Structures.1991,27(8):1035～1046
16 T.Kuwabara and M. Kuroda.Shear-Band Development in Polycrystalline Metal with Strength-Differential Effect and Plastic Volume Expansion [J].Proc.Roy.Soc.Lond.A.2002,458:2243～2259.
17 L.C.Zhang.G.Lu,S.C.Leong.V-shaped sheet forming by deformable punches [J].Journal of Materials Processing Technology.1997,(63):134～139.
18 Z.T.Zhang,S.J.Hu. Stress and residual stress distributions in plane strain bending [J].Int.J.Mech.Sci.1998,40(6):533～543
19周杰等.变薄拉延中回弹分析与实验研究.中国机械工程.2003,14(1):20～22
20张晓静,周贤宾.板料成形回弹模拟.塑性工程学报.1999,6(3):56～62
21陈毓勋.板料与型材弯曲回弹控制原理与方法.国防工业出版社,1990
22宋黎,杨坚,黄天泽.板料弯曲成形的回弹分析与工程控制综述.锻压技术.1996,(1):18～22
23李淑慧,李明哲,蔡中义,姚建国.板材多点弯曲过程及回弹现象的数值模拟.农业机械学报.2000,31(1):112～115
24刘守荣,连建设,刘玉文,孙大刚.汽车覆盖件回弹缺陷的分析.汽车技术.1997(7):39～43
25李冬升,周贤宾.双曲度覆盖件拉延回弹研究.金属成形工艺.2003,21(3):30～33
26汪晨.板料成形回弹的数值模拟及考虑回弹反向补偿的模具设计方法研究[D] .上海交通大学.1999
27李延平等.3D复杂形状板料冲压成形回弹误差补偿方法及其实验验证.塑性工程学报.2005,6(12):60～66
28邵鹏飞等.板料成形中的回弹计算和模具修正.机械强度.2001,23(2):187～189
29余国庆等.板料弯曲回弹的有限元模拟影响因素研究.模具工业.2004,(12):7～11
30单体坤等.变压边力下高强度钢板的回弹研究.塑性工程学报.2005,12(12):56～59
31郭玉琴等.覆盖件冲压加工中回弹预测的研究.机床与液压.2005,(3):54～55
32柴海啸等.基于几何回弹量补偿的模具型面修正方法.模具工业.2006,32 (11):9～12
33徐炳坤,施法中,陈中奎.板料冲压成形数值模拟的几个关键问题.塑性工程学报,2001,8 (2):32-3 5
34钟志华,张维刚,曹立波.汽车碰撞安全技术.北京:机械工业出版社,2003:51~76
35 Anon . Numerical Simulation of Sheet Forming Processes.Sheet MetalIndustries.1995,(72):46~57
36王仲仁,苑世剑,胡连喜.弹性与塑性力学基础.哈尔滨:哈尔滨工业大学出版社,2000
37张晓静,周贤宾.板料成形回弹模拟.塑性工程学报.1999,6(3):56~ 62
38 Gang Fang, Pan Zeng, Lulian Lou.Finite Element Simulation of the Effect Of Clearance on the Forming Quality in the Blanking Process.Journal of Materials Processing Technology.2002,122:249~254
39张高贤.U形件成形工艺参数优化研究.杭州:浙江大学硕士学位论文.2004:26～27
40 Q.V.Bui, L.Papeleux, J.P.Ponthot.Numerical Simulation of Springback Using Enhanced Assumed Strain Elements . Journal of Materials Processing Technology.2004,153:314~318
41 M.J.Finn,P.C.Galbraith,L.Wu.Use of a Coupled Explicit Implicit Solver for Calculating Springback in Automotive Body Panels.J. of Materials Processes Tech.1995,50:395~409
42陈炜等.板料多步冲压回弹的数值模拟研究.塑性工程学报.2005,12(5):8~11
43张渤涛.复杂形状汽车覆盖件成形过程数值仿真模式的研究.山东大学硕士学位论文.2005:7~26
44闫辉.板料成形数值模拟及回弹研究.南京理工大学硕士论文.2004:7~12
45朱东波,孙砚,李涤尘等.板料成形回弹问题研究进展.塑性工程学报.2000,7(1):11～17
46张立力,齐恬,戴映荣.数值模拟参数和工艺参数对板材成形回弹影响的研究.锻压技术.2002,(6):8～21
47刘克进,薄板冲压回弹试验研究及有限元模拟对比分析.长沙:湖南大学硕士学文论文.2004:11～15
48李建华,胡道钟等.汽车覆盖件板料成形数值模拟和工程应用关键技术研究.汽车科技.2002:36～37
49 C.Z.Sun,G.l.Chen, Z.Q.Lin,etal. Improvement of the formability of box deepdrawing using variable blank - holder forces[J]. Journal of ShanghaiJiaotong University,2003, 37(12):1883～1886
50王晓林,周贤宾.板料成形接触摩擦过程的有限元模拟技术研究闭.塑性工程学报.2000,7(1):18～21
51 H.B.Shim, E.K.Suh.Contact Treatment Algorithm for the Trimmed NURBS Surface and Analyses of Deep Drawings with Iges Surface Data.Proc.of NUMISHEET’99.France.1999:215~220
52 LS-DYNA USER'S MANUAL Version 950. Livermore Software Technology Corporation.1999
53陈文亮.板料成形CAE分析教程.北京:北京机械工业出版社,2005:202～203
54 D.Y.Yang,D.W.Jung,I.S.Song,etal.ComparativeInvestigationinto Implicit, explicit,and iterative implicit/explicit schemes for the simulation of sheet-metal forming processes[J].Journal of Materials Processing Technology,1995 (50):39～53
55 A. M .P rior. Application of Implicit and Explicit FETechniques to Metal Forming[J].Journal of Materials Processing Technology 1994 ,45:649
56王风琴,赵军,官英平,马丽霞.盒形件拉延过程中法兰区应力解析.哈尔滨工业大学学报.2003,4(35):488～490
57汪晨,张质良.利用板料反向回弹补偿模具设计新方法.锻压技术,2000,(4): 11～15
58林忠钦.车身覆盖件冲压成形仿真.北京:机械工业出版社,2005:304～305
2钟志华,李光耀.薄板冲压成形过程的计算机仿真与应用.北京理工大出版社,1998:5～8
3丰慧珍.先进高强度钢板冲压成形回弹的预测与控制.重庆:重庆大学硕士学文论文.2007:1～5
4 Makinouchi A,Kawka M.Process Simulation in Sheet Metal orming[J].Journal of Materials Processing Technology.1994,46:291～307
5 D.Zhoua, R.Wagonera H.Development and application of sheet-forming simulation[J].Journal of Materials Processing Technology.1995,(50):1～16
6余同希,张亮炽.塑性弯曲理论及其应用.北京:科学出版社,1992:45～86,181～187
7 H.Z.Dong. Z.Q.Lin.Investigation of sheet metal forming by numerical simulation and xperiment.J.Mater.Process.Technol.2000,(103):404～410
8官英平,赵军.板材V形自由弯曲智能化控制技术.研究与应用.2005,(12):1
9 Taylor L.Cao J.Karafillis A P,et al.Numerical simulations of sheet-metal forming[J].Journal of Materials Processing Technology.1995,(50): 168～179
10王孝培.实用冲压技术手册.北京:机械工业出版社,2001:13～15
11 Hill.R.塑性数学理论.王仁等译.北京:科学出版社,1966:312～319
12 Leu.D.K.A simplified approach for evaluating bendability and springback in plastic bending of anisotropic sheet metals [J].Journal of Materials Processing Technology.1997,(66):9～17
13 M.L.Wenner.On Work Hardening and Springback in Plane Strain Draw Forming [J].Applied Metal Working.1983,2(4):277
14 K.J.Weinmann,A.H.Rossenberger,etc.The Bauschinger effect of sheet metal under cyclic reverse pure bending [J].Annals of CIRP.1998,37(1):289
15 C.C.Chu.The effect of restraining force on springback [J].International Journal of Solid and Structures.1991,27(8):1035～1046
16 T.Kuwabara and M. Kuroda.Shear-Band Development in Polycrystalline Metal with Strength-Differential Effect and Plastic Volume Expansion [J].Proc.Roy.Soc.Lond.A.2002,458:2243～2259.
17 L.C.Zhang.G.Lu,S.C.Leong.V-shaped sheet forming by deformable punches [J].Journal of Materials Processing Technology.1997,(63):134～139.
18 Z.T.Zhang,S.J.Hu. Stress and residual stress distributions in plane strain bending [J].Int.J.Mech.Sci.1998,40(6):533～543
19周杰等.变薄拉延中回弹分析与实验研究.中国机械工程.2003,14(1):20～22
20张晓静,周贤宾.板料成形回弹模拟.塑性工程学报.1999,6(3):56～62
21陈毓勋.板料与型材弯曲回弹控制原理与方法.国防工业出版社,1990
22宋黎,杨坚,黄天泽.板料弯曲成形的回弹分析与工程控制综述.锻压技术.1996,(1):18～22
23李淑慧,李明哲,蔡中义,姚建国.板材多点弯曲过程及回弹现象的数值模拟.农业机械学报.2000,31(1):112～115
24刘守荣,连建设,刘玉文,孙大刚.汽车覆盖件回弹缺陷的分析.汽车技术.1997(7):39～43
25李冬升,周贤宾.双曲度覆盖件拉延回弹研究.金属成形工艺.2003,21(3):30～33
26汪晨.板料成形回弹的数值模拟及考虑回弹反向补偿的模具设计方法研究[D] .上海交通大学.1999
27李延平等.3D复杂形状板料冲压成形回弹误差补偿方法及其实验验证.塑性工程学报.2005,6(12):60～66
28邵鹏飞等.板料成形中的回弹计算和模具修正.机械强度.2001,23(2):187～189
29余国庆等.板料弯曲回弹的有限元模拟影响因素研究.模具工业.2004,(12):7～11
30单体坤等.变压边力下高强度钢板的回弹研究.塑性工程学报.2005,12(12):56～59
31郭玉琴等.覆盖件冲压加工中回弹预测的研究.机床与液压.2005,(3):54～55
32柴海啸等.基于几何回弹量补偿的模具型面修正方法.模具工业.2006,32 (11):9～12
33徐炳坤,施法中,陈中奎.板料冲压成形数值模拟的几个关键问题.塑性工程学报,2001,8 (2):32-3 5
34钟志华,张维刚,曹立波.汽车碰撞安全技术.北京:机械工业出版社,2003:51~76
35 Anon . Numerical Simulation of Sheet Forming Processes.Sheet MetalIndustries.1995,(72):46~57
36王仲仁,苑世剑,胡连喜.弹性与塑性力学基础.哈尔滨:哈尔滨工业大学出版社,2000
37张晓静,周贤宾.板料成形回弹模拟.塑性工程学报.1999,6(3):56~ 62
38 Gang Fang, Pan Zeng, Lulian Lou.Finite Element Simulation of the Effect Of Clearance on the Forming Quality in the Blanking Process.Journal of Materials Processing Technology.2002,122:249~254
39张高贤.U形件成形工艺参数优化研究.杭州:浙江大学硕士学位论文.2004:26～27
40 Q.V.Bui, L.Papeleux, J.P.Ponthot.Numerical Simulation of Springback Using Enhanced Assumed Strain Elements . Journal of Materials Processing Technology.2004,153:314~318
41 M.J.Finn,P.C.Galbraith,L.Wu.Use of a Coupled Explicit Implicit Solver for Calculating Springback in Automotive Body Panels.J. of Materials Processes Tech.1995,50:395~409
42陈炜等.板料多步冲压回弹的数值模拟研究.塑性工程学报.2005,12(5):8~11
43张渤涛.复杂形状汽车覆盖件成形过程数值仿真模式的研究.山东大学硕士学位论文.2005:7~26
44闫辉.板料成形数值模拟及回弹研究.南京理工大学硕士论文.2004:7~12
45朱东波,孙砚,李涤尘等.板料成形回弹问题研究进展.塑性工程学报.2000,7(1):11～17
46张立力,齐恬,戴映荣.数值模拟参数和工艺参数对板材成形回弹影响的研究.锻压技术.2002,(6):8～21
47刘克进,薄板冲压回弹试验研究及有限元模拟对比分析.长沙:湖南大学硕士学文论文.2004:11～15
48李建华,胡道钟等.汽车覆盖件板料成形数值模拟和工程应用关键技术研究.汽车科技.2002:36～37
49 C.Z.Sun,G.l.Chen, Z.Q.Lin,etal. Improvement of the formability of box deepdrawing using variable blank - holder forces[J]. Journal of ShanghaiJiaotong University,2003, 37(12):1883～1886
50王晓林,周贤宾.板料成形接触摩擦过程的有限元模拟技术研究闭.塑性工程学报.2000,7(1):18～21
51 H.B.Shim, E.K.Suh.Contact Treatment Algorithm for the Trimmed NURBS Surface and Analyses of Deep Drawings with Iges Surface Data.Proc.of NUMISHEET’99.France.1999:215~220
52 LS-DYNA USER'S MANUAL Version 950. Livermore Software Technology Corporation.1999
53陈文亮.板料成形CAE分析教程.北京:北京机械工业出版社,2005:202～203
54 D.Y.Yang,D.W.Jung,I.S.Song,etal.ComparativeInvestigationinto Implicit, explicit,and iterative implicit/explicit schemes for the simulation of sheet-metal forming processes[J].Journal of Materials Processing Technology,1995 (50):39～53
55 A. M .P rior. Application of Implicit and Explicit FETechniques to Metal Forming[J].Journal of Materials Processing Technology 1994 ,45:649
56王风琴,赵军,官英平,马丽霞.盒形件拉延过程中法兰区应力解析.哈尔滨工业大学学报.2003,4(35):488～490
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