数控弯管成形质量分析及数值模拟系统集成
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摘要
随着工业生产和科学技术的不断发展,管材的弯曲加工,在金属结构、工程机械、石油化工、动力机械以及锅炉、轻工、航空航天、管道工程等工业部门,占有着越来越重要的地位,也对管材的加工技术提出了更高、更新的要求。这就使得对管材弯成形质量缺陷的预测和控制成为研究与发展管材弯曲成形技术迫切需要解的难题。
本文基于电站锅炉弯管,深入的进行了对数控弯管成形技术的相关问题的研究。在对国内外学者对数控弯管成形质量研究现状的分析基础上,分析弯管受力情况,建立数控弯管理论力学模型。介绍冷弯管加工过程,定义回弹角的计算;介绍塑性成形理论,分析塑性成形中的屈服准则、流动各向同性硬化、塑性本构关系以及推导了塑性求解过程;分析弯管过程受力分析,得到弯曲管件截面上轴向应力的分布,推导出了弯管回弹角的计算公式。通过对有限元分析中材料本构关系的确定、接触边界条件的处理、求解算法的确定等关键技术的处理,运用大型非线性有限元分析软件Marc,建立了数控弯管有限元模型。通过本模型的运算分析,可以对影响弯管成形质量和弯曲回弹量有影响的因素进行分析。实际应用表明通过改善这些因素可以来提高弯管的成形质量和得到准确的弯管成形角。
在上述相关技术的研究基础上,本文基于成熟的商业软件VC++6.0集成弯管CAD/CAPP/CAE系统,成功加载了Proe二次开发模块、ansys有限元分析模块、CAPP工艺设计模块、Marc结果分析模块加载智能控制系统模块,开发了简单明了的人机界面,实现了CAD、CAPP、CAE之间数据无障碍传输,缩短了设计生产周期。
With the development of industry production and technology , the processing of tube-bending has been more and more important in many industrial sectors such as structural hardware, engineering machine, power machine, boiler, light industry and aeronautics and space industry, but at the same time higher and more advanced tube-bending technology is required. The prediction and control of tube shaping defection and improvement of tube bending technology have become tough problems to be solved.
This paper is based on the bending process of power station boiler tube, and I studied the relevant issues of NC tube bending technology in depth. I analyzed present researches of the shaping quality of NC tube bending from home and abroad, and based on these analyses, I analyzed the working condition of the tube when being bended and established the theoretical mechanics model of NC tube bending. I also introduced the process of tube cold bending, defined the calculation of the spring back angle, introduced the plastic forming theory, analyzed the yield criterion of plastic forming process, fluxion isotropic hardening, plastic constitution relationship and derived the plastic solve process. By analyzing the working condition of the tube being bended, I got the axial stress distribution on the section of the curved tube, and then derived the calculating formula of the spring back angle. The NC tube bending FEA model was built in large nonlinear finite element software--Marc by setting the material construction relationship of FEA method, handling the boundary condition, setting the solving algorithm and handling other critical technology. The factors that can influence the tube bending quality and the spring back quantity can be analyzed by arithmetic analysis of the model. And the practical applications shows that we can improve the shaping quality and the accuracy of the shaping angle by improve those factors.
Based on studies of relative technology, the integrated CAD/CAPP/CAE bending system based on mutual commercial software–VC++6.0 has been developed, which has successfully loaded Pro/E re-develop module, FEA module based on ANSYS, CAPP module and result analysis module based on Marc, I also developed a simple human-computer interface. Data transmission without obstacles is realized by this integrated system and the design cycle was reduced.
本文基于电站锅炉弯管,深入的进行了对数控弯管成形技术的相关问题的研究。在对国内外学者对数控弯管成形质量研究现状的分析基础上,分析弯管受力情况,建立数控弯管理论力学模型。介绍冷弯管加工过程,定义回弹角的计算;介绍塑性成形理论,分析塑性成形中的屈服准则、流动各向同性硬化、塑性本构关系以及推导了塑性求解过程;分析弯管过程受力分析,得到弯曲管件截面上轴向应力的分布,推导出了弯管回弹角的计算公式。通过对有限元分析中材料本构关系的确定、接触边界条件的处理、求解算法的确定等关键技术的处理,运用大型非线性有限元分析软件Marc,建立了数控弯管有限元模型。通过本模型的运算分析,可以对影响弯管成形质量和弯曲回弹量有影响的因素进行分析。实际应用表明通过改善这些因素可以来提高弯管的成形质量和得到准确的弯管成形角。
在上述相关技术的研究基础上,本文基于成熟的商业软件VC++6.0集成弯管CAD/CAPP/CAE系统,成功加载了Proe二次开发模块、ansys有限元分析模块、CAPP工艺设计模块、Marc结果分析模块加载智能控制系统模块,开发了简单明了的人机界面,实现了CAD、CAPP、CAE之间数据无障碍传输,缩短了设计生产周期。
With the development of industry production and technology , the processing of tube-bending has been more and more important in many industrial sectors such as structural hardware, engineering machine, power machine, boiler, light industry and aeronautics and space industry, but at the same time higher and more advanced tube-bending technology is required. The prediction and control of tube shaping defection and improvement of tube bending technology have become tough problems to be solved.
This paper is based on the bending process of power station boiler tube, and I studied the relevant issues of NC tube bending technology in depth. I analyzed present researches of the shaping quality of NC tube bending from home and abroad, and based on these analyses, I analyzed the working condition of the tube when being bended and established the theoretical mechanics model of NC tube bending. I also introduced the process of tube cold bending, defined the calculation of the spring back angle, introduced the plastic forming theory, analyzed the yield criterion of plastic forming process, fluxion isotropic hardening, plastic constitution relationship and derived the plastic solve process. By analyzing the working condition of the tube being bended, I got the axial stress distribution on the section of the curved tube, and then derived the calculating formula of the spring back angle. The NC tube bending FEA model was built in large nonlinear finite element software--Marc by setting the material construction relationship of FEA method, handling the boundary condition, setting the solving algorithm and handling other critical technology. The factors that can influence the tube bending quality and the spring back quantity can be analyzed by arithmetic analysis of the model. And the practical applications shows that we can improve the shaping quality and the accuracy of the shaping angle by improve those factors.
Based on studies of relative technology, the integrated CAD/CAPP/CAE bending system based on mutual commercial software–VC++6.0 has been developed, which has successfully loaded Pro/E re-develop module, FEA module based on ANSYS, CAPP module and result analysis module based on Marc, I also developed a simple human-computer interface. Data transmission without obstacles is realized by this integrated system and the design cycle was reduced.
引文
[1]王同海.管材塑性加工技术[M].北京:机械工业出版社,1998:28-29.
[2]杨合,林艳,孙志超.面向21世纪的先进塑性加工技术与管成形研究发展[C].中国科学协会第二届学术年会文集, 2000: 745-746.
[3]詹梅,杨合,江志强.管材弯曲成形的国内外研究现状及发展趋势.机械科学与技术[J], 2004, 23(12): 1509-1514.
[4] Stachowicz F. Bending with upsetting of copper tube elbows [J]. Journal of Materials Processing Technology, 2000. 100: 236—240.
[5] LOU Hua-zhou, STELSON K A. Three-dimensional tube geometry control for rotary draw tube bending, part 1: bend angle and overall tube geometry control [J]. Journal of Manufacturing Science And Engineering, 2001, 123: 258?265.
[6] LOU Hua-zhou, STELSON K A. Three-dimensional tube geometry control for rotary draw tube bending, part 2: statistical tube tolerance analysis and adaptive bend correction [J]. Journal of Manufacturing Science and Engineering, 2001, 123: 266?271.
[7] Pan K, STELSON K A. On the plastic deformation of a tube during bending[J]. Journal of Engineering for Industry Transactions of the ASME, 1995, 117: 494-499.
[8] Arild H. Clausen, Odd S. Hopperstad,Magnus Langseth. Senstivity of model parameters in stretch bending of aluminium extrusions[J]. International Journal of Mechanical Sciences 2001, 43: 427~453.
[9] O. S. Hopperstad, B. J. Leira, S. Remseth, E. Tromborg.Reliability-based analysis of a streth-bending process for aluminium extrusions[J]. Computers and Structures 1999,71:63~75.
[10] HU Z, Li J Q. Computer simulation of pipe-bending processes with small bending radius using local induction heating[J]. Journal of Materials Processing Technology, 1999, 91: 75-79.
[11]李恒,杨合,詹梅,寇永乐,谷瑞杰.大口径薄壁小弯曲半径数控弯管有限元建模和实验[J].锻压技术, 2006, 05: 136?139.
[12] Lin Y,Yang H. Thin-walled tube precision bending process and FEM simulation[J]. Transactions of Nonferrous Metals Society of China, 2006, 16(z1): 632-638.
[13]岳永保,杨合,詹梅等.薄壁管小弯曲半径数控弯曲壁厚减薄实验研究[J].锻压技术, 2007, 32(5): 58-62.
[14]寇永乐.铝合金薄壁管小弯曲半径数控弯曲成形的实验研究[J].塑性工程学报, 2007, 14(4): 29-34.
[15]鄂大辛,宁汝新,李延民,田鑫.弯管壁厚减薄与材料特性关系的试验研究[J].材料科学与工艺, 2008, 16 (No.2) :200-203 .
[16] D X E, H H He, X Y Liu, R X Ning. Spring-back deformation in tube bending. International Journal of Minerals[J]. Metallurgy and Materials, 2009, 16 (2): 177-183.
[17]胡福泰.异型管材与型材无模弯曲工艺理论及实验研究[D].东北重型机械学院博士论文, 1995.
[18]尹霞.数控弯管机弯管技术及其应用[J].新技术新工艺, 2007, 4: 27-29.
[19]李振强,王永军,王俊彪等.数控弯管工艺知识库研究[J].机械设计与制造, 2007, 8: 85-87.
[20]李振强.大直径薄壁导管数控弯曲回弹解析及工艺数据库[D].西北工业大学硕士学位论文, 2007.
[21] A. Megharbel, G.A. Nasser, and A. Domiaty. Bending of tube and section made of strain-hardening materials [J]. Mater. Process. Technol., 2008, 203: 372-380.
[22] WolpawJ R, BirbaumerN, Heetderks W J, et al. Brain_com-puter interface technology: a review of the first internationalmeeting[J]. IEEETrans. Rehabil. Eng., 2000, 8(2): 222-225.
[23]戴毅,曾卫东,杨英丽.钛合金环形管成形模具参数优化[J].稀有金属材料与工程, 2009, 38(10): 1081-1085
[24]杜长城,王俊翔,陈杰富等.锅炉弯管缠绕式冷弯成形工艺及其回弹的数值模拟[J].四川大学学报(工程科学版), 2008, 40(6): 75-79
[25]郭玲,杨合,邱晞等.具有预成形设计的薄壁弯管数据库管理系统的研究与开发[J].塑性工程学报, 2007, 14(2): 80-85.
[26]蔡东海,顾江萍,屠立群.基于OpenCASCADE软件的弯管仿真系统[J].轻工机械, 2009, 27(1): 36-38.
[27]张吉辉,丁国富,许明恒.数控弯管精确下料长度的确定和下料方案优化[J].机械设计与制造, 2009, (2): 50-52.
[28] Frode Paulsen, Torgeir Welo. Application of numerical simulation in the bending of aluminum alloy profiles[J]. Journal of Materials Processing Technology, 1996, 58: 274-285.
[29]吴建军,张萍,何朝阳.大直径薄壁弯管回弹的有限元模拟[J].锻压装备与制造技术, 2009, 44(1): 79-81
[30]曹俊.数值模拟技术在管材推弯成形中的应用[D].合肥工业大学硕士论文, 2009.
[31]陈安明,唐承统,高战地.数控弯管加工仿真系统设计与开发[J].组合机床与自动化加工技术, 2009, 9(10): 15-18.
[32]刘光武,胡勇,王呈方.弯管回弹的理论分析[J].武汉理工大学学报, 2007, 29(02): 136-138
[33] M.Goodarzi, T.Kuboki, M.Murata. Deformation analysis for the shear bending process of circular tubes[J]. Journa of Materials Processing Technology, 2005, 162-163: 492–497.
[34] M.Goodarzi, T.Kuboki, M.Murata. Effect of initial thickness on shear bending process ofcircular tubes[J]. Journal of Materials Processing Technology, 2007, 191(1-3): 136–140.
[35] Paulsen F, Welo T. Cross-sectional deformations of rectangular hollow sections in bending: part I—experiments[J]. International Journal of Mechanical Science, 2001, 43: 109～129.
[36]张明达,马秋成等. PDM框架下的CADCAMCAPPERP集成技术研究[J].现代制造工程, 2009, 7: 27-30.
[37]刘明周.面向产品的3C数据数字化集成管理研究[D].合肥工业大学博士后学位论文, 2004.
[38]隋天中,范立敏,张禹.面向车间单元模具的CAD/CAPP/CAM系统[J].模具工业, 2000, 5: 3-5.
[39]徐威.制造业CIMS中MRPⅡ与CAD/CAPP/CAM的信息集成研究[D].昆明理工大学硕士学位论文, 1999.
[40]穆玲玲.MATLAB6与Microsoft Visual C/C++的接口技术[J].微机发展, 2003, 13(7): 3-4
[41]史贵才,葛修润.面向对象有限元程序设计及其VC++与Matlab混合编程实现[J].岩土力学, 2005, 26(12): 2005-2009
[42]廖远来.数据库编程接口及其VC++应用程序设计[J].电脑与电信, 2007, (5): 63-68.
[43]赵晓敏.在VC++开发环境下的神经网络程序设计[J].机械设计与制造, 2001, (6): 14-16.
[2]杨合,林艳,孙志超.面向21世纪的先进塑性加工技术与管成形研究发展[C].中国科学协会第二届学术年会文集, 2000: 745-746.
[3]詹梅,杨合,江志强.管材弯曲成形的国内外研究现状及发展趋势.机械科学与技术[J], 2004, 23(12): 1509-1514.
[4] Stachowicz F. Bending with upsetting of copper tube elbows [J]. Journal of Materials Processing Technology, 2000. 100: 236—240.
[5] LOU Hua-zhou, STELSON K A. Three-dimensional tube geometry control for rotary draw tube bending, part 1: bend angle and overall tube geometry control [J]. Journal of Manufacturing Science And Engineering, 2001, 123: 258?265.
[6] LOU Hua-zhou, STELSON K A. Three-dimensional tube geometry control for rotary draw tube bending, part 2: statistical tube tolerance analysis and adaptive bend correction [J]. Journal of Manufacturing Science and Engineering, 2001, 123: 266?271.
[7] Pan K, STELSON K A. On the plastic deformation of a tube during bending[J]. Journal of Engineering for Industry Transactions of the ASME, 1995, 117: 494-499.
[8] Arild H. Clausen, Odd S. Hopperstad,Magnus Langseth. Senstivity of model parameters in stretch bending of aluminium extrusions[J]. International Journal of Mechanical Sciences 2001, 43: 427~453.
[9] O. S. Hopperstad, B. J. Leira, S. Remseth, E. Tromborg.Reliability-based analysis of a streth-bending process for aluminium extrusions[J]. Computers and Structures 1999,71:63~75.
[10] HU Z, Li J Q. Computer simulation of pipe-bending processes with small bending radius using local induction heating[J]. Journal of Materials Processing Technology, 1999, 91: 75-79.
[11]李恒,杨合,詹梅,寇永乐,谷瑞杰.大口径薄壁小弯曲半径数控弯管有限元建模和实验[J].锻压技术, 2006, 05: 136?139.
[12] Lin Y,Yang H. Thin-walled tube precision bending process and FEM simulation[J]. Transactions of Nonferrous Metals Society of China, 2006, 16(z1): 632-638.
[13]岳永保,杨合,詹梅等.薄壁管小弯曲半径数控弯曲壁厚减薄实验研究[J].锻压技术, 2007, 32(5): 58-62.
[14]寇永乐.铝合金薄壁管小弯曲半径数控弯曲成形的实验研究[J].塑性工程学报, 2007, 14(4): 29-34.
[15]鄂大辛,宁汝新,李延民,田鑫.弯管壁厚减薄与材料特性关系的试验研究[J].材料科学与工艺, 2008, 16 (No.2) :200-203 .
[16] D X E, H H He, X Y Liu, R X Ning. Spring-back deformation in tube bending. International Journal of Minerals[J]. Metallurgy and Materials, 2009, 16 (2): 177-183.
[17]胡福泰.异型管材与型材无模弯曲工艺理论及实验研究[D].东北重型机械学院博士论文, 1995.
[18]尹霞.数控弯管机弯管技术及其应用[J].新技术新工艺, 2007, 4: 27-29.
[19]李振强,王永军,王俊彪等.数控弯管工艺知识库研究[J].机械设计与制造, 2007, 8: 85-87.
[20]李振强.大直径薄壁导管数控弯曲回弹解析及工艺数据库[D].西北工业大学硕士学位论文, 2007.
[21] A. Megharbel, G.A. Nasser, and A. Domiaty. Bending of tube and section made of strain-hardening materials [J]. Mater. Process. Technol., 2008, 203: 372-380.
[22] WolpawJ R, BirbaumerN, Heetderks W J, et al. Brain_com-puter interface technology: a review of the first internationalmeeting[J]. IEEETrans. Rehabil. Eng., 2000, 8(2): 222-225.
[23]戴毅,曾卫东,杨英丽.钛合金环形管成形模具参数优化[J].稀有金属材料与工程, 2009, 38(10): 1081-1085
[24]杜长城,王俊翔,陈杰富等.锅炉弯管缠绕式冷弯成形工艺及其回弹的数值模拟[J].四川大学学报(工程科学版), 2008, 40(6): 75-79
[25]郭玲,杨合,邱晞等.具有预成形设计的薄壁弯管数据库管理系统的研究与开发[J].塑性工程学报, 2007, 14(2): 80-85.
[26]蔡东海,顾江萍,屠立群.基于OpenCASCADE软件的弯管仿真系统[J].轻工机械, 2009, 27(1): 36-38.
[27]张吉辉,丁国富,许明恒.数控弯管精确下料长度的确定和下料方案优化[J].机械设计与制造, 2009, (2): 50-52.
[28] Frode Paulsen, Torgeir Welo. Application of numerical simulation in the bending of aluminum alloy profiles[J]. Journal of Materials Processing Technology, 1996, 58: 274-285.
[29]吴建军,张萍,何朝阳.大直径薄壁弯管回弹的有限元模拟[J].锻压装备与制造技术, 2009, 44(1): 79-81
[30]曹俊.数值模拟技术在管材推弯成形中的应用[D].合肥工业大学硕士论文, 2009.
[31]陈安明,唐承统,高战地.数控弯管加工仿真系统设计与开发[J].组合机床与自动化加工技术, 2009, 9(10): 15-18.
[32]刘光武,胡勇,王呈方.弯管回弹的理论分析[J].武汉理工大学学报, 2007, 29(02): 136-138
[33] M.Goodarzi, T.Kuboki, M.Murata. Deformation analysis for the shear bending process of circular tubes[J]. Journa of Materials Processing Technology, 2005, 162-163: 492–497.
[34] M.Goodarzi, T.Kuboki, M.Murata. Effect of initial thickness on shear bending process ofcircular tubes[J]. Journal of Materials Processing Technology, 2007, 191(1-3): 136–140.
[35] Paulsen F, Welo T. Cross-sectional deformations of rectangular hollow sections in bending: part I—experiments[J]. International Journal of Mechanical Science, 2001, 43: 109～129.
[36]张明达,马秋成等. PDM框架下的CADCAMCAPPERP集成技术研究[J].现代制造工程, 2009, 7: 27-30.
[37]刘明周.面向产品的3C数据数字化集成管理研究[D].合肥工业大学博士后学位论文, 2004.
[38]隋天中,范立敏,张禹.面向车间单元模具的CAD/CAPP/CAM系统[J].模具工业, 2000, 5: 3-5.
[39]徐威.制造业CIMS中MRPⅡ与CAD/CAPP/CAM的信息集成研究[D].昆明理工大学硕士学位论文, 1999.
[40]穆玲玲.MATLAB6与Microsoft Visual C/C++的接口技术[J].微机发展, 2003, 13(7): 3-4
[41]史贵才,葛修润.面向对象有限元程序设计及其VC++与Matlab混合编程实现[J].岩土力学, 2005, 26(12): 2005-2009
[42]廖远来.数据库编程接口及其VC++应用程序设计[J].电脑与电信, 2007, (5): 63-68.
[43]赵晓敏.在VC++开发环境下的神经网络程序设计[J].机械设计与制造, 2001, (6): 14-16.