高频感应弯板成形技术研究
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摘要
热应力成形是加工板料的一种重要成形方法。传统的产生热应力方法是通过火焰或激光局部加热来实现的。由于火焰或激光局部加热存在着诸多局限性,因此本文研究了一种新的板料热应力成形技术——高频感应弯板成形工艺。该工艺利用高频感应加热来代替火焰加热或激光加热来进行板料热应力弯曲成形。论文的主要工作是开发高频感应弯板成形工艺的有限元预测模型及其试验装置,研究感应加热各参数对板料弯曲成形效果的影响规律。主要内容如下:
(1)开发出高频感应弯板成形工艺的磁-热-结构多场耦合有限元预测模型。在给定工艺参数前提下,用开发的有限元模型能够预测板料弯曲变形结果。
(2)设计了数控高频感应弯板成形试验机。此试验机可用于进行高频感应弯板成形试验和生产。
(3)用设计的试验机进行了高频感应弯板成形试验研究,对有限元预测模型进行了验证,结果表明,有限元预测模型的预测精度是可以接受的,可用于指导生产。
(4)通过有限元模拟和试验研究相结合的方法,得出了主要工艺参数对高频感应弯板成形效果的影响规律。
Thermal stress forming is a important forming process of plate which is deformed. At present, the traditional approach to cause thermal stress is local heating by flame or laser. Due to a great deal of limitation of heating by flame or laser, a new thermal stress forming process——high frequency induction heating forming of plate is studied in this paper. This process heats by high frequency induction in place of flame or laser. Main research contents in this paper are developing the FEA model of high frequency induction heating forming of plate, and exploring laws of this process. Main research content as follows:
(1) The multiphysics coupled FEA model of high frequency induction heating forming of plate has been developed. Under the condition of some certain technological parameters, forming results of plate can be predicted.
(2) A experimental machine of high frequency induction heating forming of plate has been developed. This tester can be used for the experiment and production of high frequency induction heating forming of plate.
(3) The reliability of FEA model has been verified by the experiment.
(4) By means of the combined method of numerical simulation and experimental research,the laws that main process parameters impact on the bending angle of plate is gotten.
(1)开发出高频感应弯板成形工艺的磁-热-结构多场耦合有限元预测模型。在给定工艺参数前提下,用开发的有限元模型能够预测板料弯曲变形结果。
(2)设计了数控高频感应弯板成形试验机。此试验机可用于进行高频感应弯板成形试验和生产。
(3)用设计的试验机进行了高频感应弯板成形试验研究,对有限元预测模型进行了验证,结果表明,有限元预测模型的预测精度是可以接受的,可用于指导生产。
(4)通过有限元模拟和试验研究相结合的方法,得出了主要工艺参数对高频感应弯板成形效果的影响规律。
Thermal stress forming is a important forming process of plate which is deformed. At present, the traditional approach to cause thermal stress is local heating by flame or laser. Due to a great deal of limitation of heating by flame or laser, a new thermal stress forming process——high frequency induction heating forming of plate is studied in this paper. This process heats by high frequency induction in place of flame or laser. Main research contents in this paper are developing the FEA model of high frequency induction heating forming of plate, and exploring laws of this process. Main research content as follows:
(1) The multiphysics coupled FEA model of high frequency induction heating forming of plate has been developed. Under the condition of some certain technological parameters, forming results of plate can be predicted.
(2) A experimental machine of high frequency induction heating forming of plate has been developed. This tester can be used for the experiment and production of high frequency induction heating forming of plate.
(3) The reliability of FEA model has been verified by the experiment.
(4) By means of the combined method of numerical simulation and experimental research,the laws that main process parameters impact on the bending angle of plate is gotten.
引文
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[6]范平,陈明和,周兆锋等.板料无模成形技术——热应力成形.新技术新工艺,2007年,第11期:62-64。
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[14] Morinobu I, Yoshihiko T. Advanced line heating system applying FEM computer simulation. Bulletin of the Society of Naval Architects of Japan, 1999, 39(2): 60-64.
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[21] Jang C D, Moon S C. An Algorithm to determine heating lines for plate forming by line heating method. Journal of Ship Production, 1998, 14(4): 238-245.
[22] Lee J S. Development of automatic marking generation system for plate forming by line heating. Journal of Ship Production, 1996,12(4): 247-253.
[23] Moshaiov A, RLatorre. Temperature distribution during plate bending by torch flame heating. Journal of Ship Research, 1985, 29(1): 1-11.
[24] Shin J G, Moshaiov A. Modified strip model for analyzing the line heating method-Part1:Elastic Plates. Journal of Ship Research,1991, 35(2): 172-182.
[25] Moshaiov A, Shin J G. Modified strip model for analyzing the line heating method-Part 2:Thereto-Elastic-Plastic Plates. Journal of Ship Research,1991, 35(3): 266-275.
[26] Shin J G, Woo J H. Analysis of heat transfer between the gas torch and the plate for the application of line heating. Journal of manufacturing science and engineering, 2003, 125(11):794-800.
[27] Koenig P C, Narita H, Baba K. Lean production in the Japanese shipbuilding industry.Journal of Ship Production, 2002,18(3): 167-174.
[28] Yu G, Anderson R J, Maekawa T, et al. Efficient simulation of shell forming by line heating. International journal of Mechanical Sciences, 2001, 43: 2349-2370.
[29] Adak M, Manda N R Thermomechanical analysis of plates undergoing line heating using pseudolinear equivalent constant rigidity system. Journal of Ship Production, 2004, 20(2):84-89.
[30] Morinobu I, Kamichilra R, etc, Automation of plate bending process by line heating.Bulletinof the Society of Naval Architects of Japan, 1994, 34(2): 120-125.
[31]张杰刚,陈明和.板料激光成形技术.热加工工艺,2006,35(13): 87-89
[32]王秀凤,胡世光,陈光南.板料激光成形技术.锻压技术,1998(6): 32-34.
[33]季忠,王忠雷,焦学健等.板料激光弯曲成形工艺参数优化设计.锻压技术,2002(6): 38-41.
[34]石永军,姚振强,沈洪.激光热应力板料成形角变形分析.南京航空航天大学学报,2005(11): 99-103
[35]季忠,吴诗惇.板料激光弯曲成形数值模拟.中国激光,2001(10):953-956.
[36]季忠,吴诗惇，李淼泉.板料激光成形时的温度场研究.塑性工程学报,1997(6): 14-18.
[37]陈敦军,龙丽,吴诗惇.板料激光曲线弯曲成形的数值模拟.中国机械工程,2003,14(13): 1152-1155.
[38] Magee J, De Vin L J. Process planning for laser-forming. Journal of Materials ProcessingTechnology, 2002(120): 322-326.
[39] Thomas Hennige. Development of irradiation strategies for 3D-laser forming. Journal of Materials Processing Technology,2000(2):102-108.
[40] D.-J. Chen, Y.-B. Xiang, S.-C. Wu. Application of fuzzy neural network to laser bending process of sheetmetal. Materials Science and Technology,2002(6):677-680
[41] K. Scully. Laser line heating. Journal of Ship Production,1987,3(4):237-246.
[42] M. Geiger. Synergy of laser material processing and metal forming. Annals of the CIRP,1994, 43(2):563-570.
[43] Kyrsanidi A K, Kennanidis T B, Pantelakis S G. Numerical and experimentalinvestigation of the laser forming process. Journal of Materials Proceeding Technology, 1999,87: 281-290.
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