轧制差厚板成形性能研究
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摘要
节能和环保是21世纪汽车工业必须面对的两个巨大挑战,而汽车轻量化技术则是应对挑战的一项重要举措。采用新型材料(如铝镁合金、塑料、陶瓷等)和采用基于新材料加工技术的板材(如激光拼焊板、轧制差厚板等)是实现汽车轻量化的两种有效途径。然而由于钢具有较高的性价比,短期内大规模的应用新型材料来代替钢并不现实,因此基于新材料加工技术的板料便越来越受到人们的重视。
目前,激光拼焊板(TWB,Tailor Welded Blank)已经在汽车工业中得到了广泛的应用。轧制差厚板(TRB,Tailor Rolled Blank)是继激光拼焊板之后,又一种基于新材料加工技术的轻量化结构板材。柔性轧制技术是差厚板生产的核心技术,它与传统的纵轧工艺类似,但轧辊的间隙在轧制过程中可以实时调整,因而能够沿轧制方向轧制出预先定制的变截面形状。设计人员可以根据零件在成形工序中和服役过程中的实际受力情况,选择优化的板料纵向截面轮廓,极大地增加了设计灵活性。由轧制差厚板冲压成形的汽车覆盖件具有良好的刚性和强度,能够提高汽车的承载力、抗凹性和吸能性,并且能够显著地减轻车身重量。
为了推动轧制差厚板在汽车车身上的应用,对其成形性能的研究势在必行。本文采用解析分析、数值仿真与实验验证相结合的方法,对轧制差厚板的成形性能进行了研究。
应用双斜率退火工艺对轧制差厚板进行了退火处理,测试并比较了未退火和已退火差厚板的硬度。通过单向拉伸试验研究了轧制差厚板的基本力学性能,建立了差厚板单向拉伸力学解析模型,推导了差厚板薄厚两侧变形量的计算公式。以单向拉伸试验数据为基础,采用拉格朗日多项式插值法构造了未退火和已退火差厚板的应力应变场,解决了数值仿真过程中差厚板的材料参数问题。最后,将试验、解析、仿真的结果进行了对比,并且通过微观组织对拉伸试验结果进行了解释。试验、解析、仿真三者的高度吻合证明了差厚板单向拉伸力学解析模型和变形量计算公式的正确性。研究结果表明：对于未退火和已退火的差厚板拉伸试样,缩颈失效均是发生在差厚板薄侧,退火后的差厚板强度减小而塑性增强,获得了更大的延伸率。
分析了差厚板盒形件的成形原理、应力分布状态以及变形特点,介绍了差厚板盒形件的成形缺陷,包括起皱、破裂、过渡区移动等,探讨了缺陷产生的机理,确定了缺陷发生的位置,给出了缺陷问题的解决办法,并且在差厚板单向拉伸解析模型的基础上建立了过渡区移动量的计算公式。最后,对轧制差厚板方盒形件进行了冲爪成形仿真与实验工作。分别讨论了退火工艺、压边力类型、压边力值、板料厚度差、过渡区长度、过渡区位置、板料尺寸等因素对轧制差厚板方盒形件减薄率以及过渡区移动的影响,仿真与实验结果能够较好地吻合。
阐述了弯曲回弹机理,分析了弯曲回弹过程中的力学问题,推导了回弹量的计算公式,给出了影响回弹数值仿真精度的关键因素。在此基础上,分别对纵向弯曲(弯曲轴平行于轧制方向)和横向弯曲(弯曲轴垂直于轧制方向)的轧制差厚板U型件的回弹特性进行了研究。分析了差厚板U型件成形后的厚度分布、应力应变分布状态以及回弹趋势,讨论了模具间隙、摩擦系数、材料性能、板料尺寸、板料厚度、过渡区长度以及过渡区位置等因素对差厚板U型件回弹的影响,并单独讨论了上述因素对横向弯曲的差厚板U型件过渡区移动的影响。研究结果表明：仿真与实验结果有着较好的一致性。成形后轧制差厚板U型件各部分的厚度变化不大,未退火差厚板U型件薄侧的回弹量大于厚侧,退火处理能够极大地减小差厚板尤其是其薄侧的回弹量,使得整块板料的回弹比较均匀。另外,对于横向弯曲的差厚板,已退火差厚板厚度过渡区移动量要大于未退火情况。
为了实现车身的轻量化,将轧制差厚板应用于某车型的A柱加强板。通过采用加强肋以及退火工艺,零件的回弹量以及过渡区移动量均能够控制在允许的范围内。将轧制差厚板引入车身覆盖件的制造,能在满足零件强度和刚性要求的前提下,达到节约材料、减轻重量的目的。
Energy saving and environmental protection are the two great challenges that the automotive industry has to face in the21st century. The vehicle lightweight technology is an important measure to cope with these challenges. The adoptions of new materials (such as aluminum alloy, magnesium alloy, plastics, ceramics etc.) and lightweight structural metal sheets based on new material processing technology (such as Tailor Welded Blank, Tailored Rolled Blanks etc.) are two effective ways to achieve automotive lightweight. However, because of the high performance-price ratio of steel, extensive application of new materials in place of steel is unrealistic, so the metal sheets based on new material processing technology have been paid more and more attention.
So far, Tailor Welded Blank(TWB) has been widely applied in the automotive industry. Tailor Rolled Blank(TRB) is another kind of metal sheet for lightweight strcuture based on new material processing technology after TWB. Flexible rolling technology is the key technology for TRB manufacturing. It is similar to the traditional longitudinal rolling technology, but the roll gap can be adjusted through computer real-time control during rolling, and thus the blank is rolled with the preset variable section shape in the rolling direction. Designers may select the optimized longitudinal section profile of TRB according to the actual load cases in forming and serving processes, which can greatly improve the design flexiblility. Auto panels made of TRB, which have advantages of better rigidity and strength, can improve the load-carrying ability, the dent resistance and the energy absorption capacity, and significantly lighten the weight of autobody.
In order to promote the application of TRB in the automotive body, the research on the formability of TRB is imperative. The formability of TRB is studied by a combination method of analytical analysis, numerical simulation and experimental verification.
TRB is annealed by the two-slope annealing process. The hardness of unannealed and annealed TRBs is tested and compared. The basic mechanical properties of TRB are studied by the uniaxial tension test. The mechanical analytical model for uniaxial tension is set up, and the formulae of deformation at the thinner side and at the thicker side are derived. On the basis of uniaxial tension test data, the Lagrange polynomial interpolation is adopted to construct the stress and strain fields of unannealed and annealed TRBs, which can solve the problem of TRB material parameters for simulation. Finally comparison of results among experiment, analysis and simulation are carried out. and the experimental results are explained by the mierostructure. The agreement of experiment, analysis and simulation confirms the correctness of the analytical model and the deformation formulae. The results show that the necking happens at the thinner side for both unannealed and annealed TRB tension specimens, the annealed TRB has lower strength and higher plasticity, and thus acquires greater elongation.
The forming principle, the stress distribution state and the deformation characteristics of TRB box are analyzed. The forming defects are presented, including wrinkle, crack, thickness transition zone(TTZ) movement etc. The mechanisms of theses defects are discussed, the spots of the defects are fixed, and the measures solving the defects are offered. The formula of TTZ displacement is built on the basis of uniaxial tension analytical model. At the end, simulation and experiment of stamping forming process of TRB square box are carried out. Effects of annealing process, binder force type, binder force value, blank thickness difference, TTZ length, TTZ position and blank size on thinning and TTZ movement are discussed, and the numerical data and the experimental data are in good agreement.
The bending springback mechanism is described. The mechanic problems during the course of bending springback are analyzed, and the formula for computing the amount of springback is deduced. The key factors that affect the springback simulation accuracy are offered. On this basis, the springback characteristics of longitudinally bended (bending axis is parallel to the rolling direction) and transversely bended (bending axis is perpendicular to the rolling direction) TRB U-shaped parts are studied. The thickness distribution, the stress strain distribution state and the springback trend after forming are analyzed. Effects of die clearance, friction coefficient, material properties, blank size, blank thickness, TTZ length and TTZ position on the springback of TRB U-shaped part are discussed, and a separate discussion on effects of above factors on the TTZ movement of traversely bended TRB U-shaped parts is carried out. The results show that numerical and experimental results have good consistency. After forming, the thickness of the whole TRB varies little, and the springback at the thinner side is much larger than that at the thicker side for the unannealed TRB U-shaped parts. Annealing treatment can greatly reduce the springback of TRB especially the springback at the thinner side, and make the springback of the whole TRB uniform. In addition, for traversely bended U-shaped parts, the TTZ, movement of the annealed TRB is larger than that of the unannealed TRB.
For the purpose of achieving the autobody lightweight. TRB is applied to the sti Honor of A-pillar in some car. Through the use of stiffening ribs and annealing process, the springback and the TTZ movement of the TRB part can be controlled in a permitted range. The introduction of TRB into the manufacturing of panels can achieve the goals of saving material and lowering weight on the premise of meeting strength and rigidity.
目前,激光拼焊板(TWB,Tailor Welded Blank)已经在汽车工业中得到了广泛的应用。轧制差厚板(TRB,Tailor Rolled Blank)是继激光拼焊板之后,又一种基于新材料加工技术的轻量化结构板材。柔性轧制技术是差厚板生产的核心技术,它与传统的纵轧工艺类似,但轧辊的间隙在轧制过程中可以实时调整,因而能够沿轧制方向轧制出预先定制的变截面形状。设计人员可以根据零件在成形工序中和服役过程中的实际受力情况,选择优化的板料纵向截面轮廓,极大地增加了设计灵活性。由轧制差厚板冲压成形的汽车覆盖件具有良好的刚性和强度,能够提高汽车的承载力、抗凹性和吸能性,并且能够显著地减轻车身重量。
为了推动轧制差厚板在汽车车身上的应用,对其成形性能的研究势在必行。本文采用解析分析、数值仿真与实验验证相结合的方法,对轧制差厚板的成形性能进行了研究。
应用双斜率退火工艺对轧制差厚板进行了退火处理,测试并比较了未退火和已退火差厚板的硬度。通过单向拉伸试验研究了轧制差厚板的基本力学性能,建立了差厚板单向拉伸力学解析模型,推导了差厚板薄厚两侧变形量的计算公式。以单向拉伸试验数据为基础,采用拉格朗日多项式插值法构造了未退火和已退火差厚板的应力应变场,解决了数值仿真过程中差厚板的材料参数问题。最后,将试验、解析、仿真的结果进行了对比,并且通过微观组织对拉伸试验结果进行了解释。试验、解析、仿真三者的高度吻合证明了差厚板单向拉伸力学解析模型和变形量计算公式的正确性。研究结果表明：对于未退火和已退火的差厚板拉伸试样,缩颈失效均是发生在差厚板薄侧,退火后的差厚板强度减小而塑性增强,获得了更大的延伸率。
分析了差厚板盒形件的成形原理、应力分布状态以及变形特点,介绍了差厚板盒形件的成形缺陷,包括起皱、破裂、过渡区移动等,探讨了缺陷产生的机理,确定了缺陷发生的位置,给出了缺陷问题的解决办法,并且在差厚板单向拉伸解析模型的基础上建立了过渡区移动量的计算公式。最后,对轧制差厚板方盒形件进行了冲爪成形仿真与实验工作。分别讨论了退火工艺、压边力类型、压边力值、板料厚度差、过渡区长度、过渡区位置、板料尺寸等因素对轧制差厚板方盒形件减薄率以及过渡区移动的影响,仿真与实验结果能够较好地吻合。
阐述了弯曲回弹机理,分析了弯曲回弹过程中的力学问题,推导了回弹量的计算公式,给出了影响回弹数值仿真精度的关键因素。在此基础上,分别对纵向弯曲(弯曲轴平行于轧制方向)和横向弯曲(弯曲轴垂直于轧制方向)的轧制差厚板U型件的回弹特性进行了研究。分析了差厚板U型件成形后的厚度分布、应力应变分布状态以及回弹趋势,讨论了模具间隙、摩擦系数、材料性能、板料尺寸、板料厚度、过渡区长度以及过渡区位置等因素对差厚板U型件回弹的影响,并单独讨论了上述因素对横向弯曲的差厚板U型件过渡区移动的影响。研究结果表明：仿真与实验结果有着较好的一致性。成形后轧制差厚板U型件各部分的厚度变化不大,未退火差厚板U型件薄侧的回弹量大于厚侧,退火处理能够极大地减小差厚板尤其是其薄侧的回弹量,使得整块板料的回弹比较均匀。另外,对于横向弯曲的差厚板,已退火差厚板厚度过渡区移动量要大于未退火情况。
为了实现车身的轻量化,将轧制差厚板应用于某车型的A柱加强板。通过采用加强肋以及退火工艺,零件的回弹量以及过渡区移动量均能够控制在允许的范围内。将轧制差厚板引入车身覆盖件的制造,能在满足零件强度和刚性要求的前提下,达到节约材料、减轻重量的目的。
Energy saving and environmental protection are the two great challenges that the automotive industry has to face in the21st century. The vehicle lightweight technology is an important measure to cope with these challenges. The adoptions of new materials (such as aluminum alloy, magnesium alloy, plastics, ceramics etc.) and lightweight structural metal sheets based on new material processing technology (such as Tailor Welded Blank, Tailored Rolled Blanks etc.) are two effective ways to achieve automotive lightweight. However, because of the high performance-price ratio of steel, extensive application of new materials in place of steel is unrealistic, so the metal sheets based on new material processing technology have been paid more and more attention.
So far, Tailor Welded Blank(TWB) has been widely applied in the automotive industry. Tailor Rolled Blank(TRB) is another kind of metal sheet for lightweight strcuture based on new material processing technology after TWB. Flexible rolling technology is the key technology for TRB manufacturing. It is similar to the traditional longitudinal rolling technology, but the roll gap can be adjusted through computer real-time control during rolling, and thus the blank is rolled with the preset variable section shape in the rolling direction. Designers may select the optimized longitudinal section profile of TRB according to the actual load cases in forming and serving processes, which can greatly improve the design flexiblility. Auto panels made of TRB, which have advantages of better rigidity and strength, can improve the load-carrying ability, the dent resistance and the energy absorption capacity, and significantly lighten the weight of autobody.
In order to promote the application of TRB in the automotive body, the research on the formability of TRB is imperative. The formability of TRB is studied by a combination method of analytical analysis, numerical simulation and experimental verification.
TRB is annealed by the two-slope annealing process. The hardness of unannealed and annealed TRBs is tested and compared. The basic mechanical properties of TRB are studied by the uniaxial tension test. The mechanical analytical model for uniaxial tension is set up, and the formulae of deformation at the thinner side and at the thicker side are derived. On the basis of uniaxial tension test data, the Lagrange polynomial interpolation is adopted to construct the stress and strain fields of unannealed and annealed TRBs, which can solve the problem of TRB material parameters for simulation. Finally comparison of results among experiment, analysis and simulation are carried out. and the experimental results are explained by the mierostructure. The agreement of experiment, analysis and simulation confirms the correctness of the analytical model and the deformation formulae. The results show that the necking happens at the thinner side for both unannealed and annealed TRB tension specimens, the annealed TRB has lower strength and higher plasticity, and thus acquires greater elongation.
The forming principle, the stress distribution state and the deformation characteristics of TRB box are analyzed. The forming defects are presented, including wrinkle, crack, thickness transition zone(TTZ) movement etc. The mechanisms of theses defects are discussed, the spots of the defects are fixed, and the measures solving the defects are offered. The formula of TTZ displacement is built on the basis of uniaxial tension analytical model. At the end, simulation and experiment of stamping forming process of TRB square box are carried out. Effects of annealing process, binder force type, binder force value, blank thickness difference, TTZ length, TTZ position and blank size on thinning and TTZ movement are discussed, and the numerical data and the experimental data are in good agreement.
The bending springback mechanism is described. The mechanic problems during the course of bending springback are analyzed, and the formula for computing the amount of springback is deduced. The key factors that affect the springback simulation accuracy are offered. On this basis, the springback characteristics of longitudinally bended (bending axis is parallel to the rolling direction) and transversely bended (bending axis is perpendicular to the rolling direction) TRB U-shaped parts are studied. The thickness distribution, the stress strain distribution state and the springback trend after forming are analyzed. Effects of die clearance, friction coefficient, material properties, blank size, blank thickness, TTZ length and TTZ position on the springback of TRB U-shaped part are discussed, and a separate discussion on effects of above factors on the TTZ movement of traversely bended TRB U-shaped parts is carried out. The results show that numerical and experimental results have good consistency. After forming, the thickness of the whole TRB varies little, and the springback at the thinner side is much larger than that at the thicker side for the unannealed TRB U-shaped parts. Annealing treatment can greatly reduce the springback of TRB especially the springback at the thinner side, and make the springback of the whole TRB uniform. In addition, for traversely bended U-shaped parts, the TTZ, movement of the annealed TRB is larger than that of the unannealed TRB.
For the purpose of achieving the autobody lightweight. TRB is applied to the sti Honor of A-pillar in some car. Through the use of stiffening ribs and annealing process, the springback and the TTZ movement of the TRB part can be controlled in a permitted range. The introduction of TRB into the manufacturing of panels can achieve the goals of saving material and lowering weight on the premise of meeting strength and rigidity.
引文
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