典型截面辊弯成型变形区及力能参数研究
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摘要
辊弯成型在板材成形领域占有十分重要的位置,它是一种经济、环保和节能的生产工艺。特别是高强度钢出现后,为了能够生产出高质量的辊弯成型产品,需要对辊弯成型工艺不断进行改进和完善,这就要求对辊弯成型过程中的相关参数进行分析研究,如弯曲角、弯曲半径、变形区长度、成型力矩和成型力等。然而,目前国内外对此进行研究的不多,特别是成型过程中的力能参数研究成果更少。
本文通过对国内外辊弯成型相关文献的研究,综述了辊弯成型方面的实际应用和理论研究状况。重点对辊弯成型变形区和力能参数进行了理论上的分析研究和仿真验证。根据实际进行简化假设,根据能量法得出了力能参数研究计算的几何模型,分析推导出了辊弯成型过程中的总的变形能、总功和总功率,计算得出了弯曲角计算表达式及其纵向分布图,解析出了变形区长度计算公式,并且解析出了辊弯成型力矩和成型力的理论计算表达式,并且对其影响因素进行了分析。
为了验证所研究得出的力能参数的正确性,本文进行了辊弯成型力能参数仿真实验。基于正交实验的方法,设计了实验方案,对不同影响因素的不同水平分别进行了仿真实验,得出了成型力矩和成型力的仿真计算数值。通过理论计算值和仿真实验数值的对比分析,确认二者的相符合程度较好,证明了理论推导出的计算表达式的合理性。
本文经过理论推导和仿真验证,得出的辊弯成型力能参数计算表达式,能够为辊弯成型理论研究、产品设计和生产制造提供理论参考。
Roll forming has a very important position in the field of sheet forming, it is an production process of economical, environmentally friendly, energy-saving and has strong vitality. In order to be able to produce various sorts and varieties of high-quality roll forming products, we should continuously improve and refine roll forming process, this is necessary to research the relevant parameters in the roll forming process, furthermore, R&D roll forming equipment also should clearly know the relevant parameters, such as the bending angle, bending radius, deformation length, forming moment and forming force and so on. However, at present it is has very little research about this at home and abroad, especially it has less research about the roll forming force and moment parameters in the forming process.
In this article, it review the practical application and theoretical research status of the roll forming, through the learning of roll forming relevant literature in home and abroad. Emphasis on force and energy parameters research of roll forming. Based on theoretical assumptions, the geometric model is simplified, deduced the total deformation power in the roll forming process, the bending angle calculation expression and its vertical distribution map has been calculated, parse out the formula of the deformation length, forming moment and the forming force, and analysis of the influencing factors.
In order to verify the correctness of the force and power parameters, in this article carried out the roll forming force and energy simulation experiments. Based on orthogonal experiment design the experiment scheme, do a series of simulation experiments about the different levels of the different factors, obtain the simulation values. Through the comparative analysis of the calculated values and simulation values, it proved the correctness of the theoretical derivation of the formula.
In this article, through theoretical analysis and simulation, obtained the calculation expression of force and energy parameters of roll forming, can provide theoretical reference for roll forming theoretical research, product design and manufacturing.
本文通过对国内外辊弯成型相关文献的研究,综述了辊弯成型方面的实际应用和理论研究状况。重点对辊弯成型变形区和力能参数进行了理论上的分析研究和仿真验证。根据实际进行简化假设,根据能量法得出了力能参数研究计算的几何模型,分析推导出了辊弯成型过程中的总的变形能、总功和总功率,计算得出了弯曲角计算表达式及其纵向分布图,解析出了变形区长度计算公式,并且解析出了辊弯成型力矩和成型力的理论计算表达式,并且对其影响因素进行了分析。
为了验证所研究得出的力能参数的正确性,本文进行了辊弯成型力能参数仿真实验。基于正交实验的方法,设计了实验方案,对不同影响因素的不同水平分别进行了仿真实验,得出了成型力矩和成型力的仿真计算数值。通过理论计算值和仿真实验数值的对比分析,确认二者的相符合程度较好,证明了理论推导出的计算表达式的合理性。
本文经过理论推导和仿真验证,得出的辊弯成型力能参数计算表达式,能够为辊弯成型理论研究、产品设计和生产制造提供理论参考。
Roll forming has a very important position in the field of sheet forming, it is an production process of economical, environmentally friendly, energy-saving and has strong vitality. In order to be able to produce various sorts and varieties of high-quality roll forming products, we should continuously improve and refine roll forming process, this is necessary to research the relevant parameters in the roll forming process, furthermore, R&D roll forming equipment also should clearly know the relevant parameters, such as the bending angle, bending radius, deformation length, forming moment and forming force and so on. However, at present it is has very little research about this at home and abroad, especially it has less research about the roll forming force and moment parameters in the forming process.
In this article, it review the practical application and theoretical research status of the roll forming, through the learning of roll forming relevant literature in home and abroad. Emphasis on force and energy parameters research of roll forming. Based on theoretical assumptions, the geometric model is simplified, deduced the total deformation power in the roll forming process, the bending angle calculation expression and its vertical distribution map has been calculated, parse out the formula of the deformation length, forming moment and the forming force, and analysis of the influencing factors.
In order to verify the correctness of the force and power parameters, in this article carried out the roll forming force and energy simulation experiments. Based on orthogonal experiment design the experiment scheme, do a series of simulation experiments about the different levels of the different factors, obtain the simulation values. Through the comparative analysis of the calculated values and simulation values, it proved the correctness of the theoretical derivation of the formula.
In this article, through theoretical analysis and simulation, obtained the calculation expression of force and energy parameters of roll forming, can provide theoretical reference for roll forming theoretical research, product design and manufacturing.
引文
[1]韩飞,刘继英,艾正青等.辊弯成形技术理论及应用研究现状[J].塑性工程学报,2010,(17)：1～5
[2]王春新,刘继英.冷弯成形过程仿真技术的发展[J].北方工业大学学报,2004,16(1)：46～50
[3]韩志武,刘才,陆卫平.辊弯成型工艺、理论及CAE技术研究进展与展望[J].钢铁,1999,34(7)：70～76
[4]K Nakajima, W Miznutani et, al. Development of new vertical roll forming process for ERW pipe. Nippon Steel Technical Report, 1980, 8(15):127-144
[5]Terrt R Walker, Roy J Pick. Approximation of the Axial Strains Developed During the Roll Forming of Pipe. J. Mater. Process. Technol, 1990, 22:29-44
[7]崔高健,吕相艳,迟正洪.冷弯型钢成型技术的发展现状[J].机械制造,2005,43(494)：41-44
[8]赵璞.基于有限元数值模拟的不锈钢冷弯成型扭曲的研究[硕士学位论文].长春：长春工业大学,2007
[9]Alexander S. Galakhar, Paul A. Meehan, William J.T. Daniel, and Shi Chao Ding. A method of approximate tool wear analysis in cold roll forming 5th Australasian[C]//. Congress on Applied Mechanics, ACAM 2007
[10]习荣堂,李景方.冷弯成型过程中变形过渡区的研究[J].东北大学学报,16(6)：593-597
[11]李景芳,习荣堂.冷弯型钢成型力能参数研究[J].《重型机械》,1994(1)：47-50
[12]习荣堂,李景方,樊永义.冷弯成型力研究[J].东北大学学报,1996,17(1)：94-97
[13]樊永义,杨莅彦.冷弯槽钢变形过渡区长度的计算[J].冶金设备,2000,(5)：1-5
[14]丁国良.冷弯型钢中力能参数的理论推导[C]//.2005中国国际冷弯型钢研讨会论文集,2005,1～10
[15]兑关锁.冷弯型钢纵向变形的理论分析及计算[J].钢铁研究学报,1997,(2)：1-3
[16]岳崇锋,余万华,冯光宏.冷弯成型技术研究现状[C]//.第六届华北(扩大)塑性加工学术年会论文集,北京：北京科技大学,2009,44-49
[17]陈锡栋,杨婕,赵晓栋等.有限元法的发展现状及应用[J]；中国制造业信息化,2010,11：6-8
[18]马航.板带矫正机的模拟研究[硕士学位论文].武汉：武汉科技大学,2010
[19]] Sukmoo Hong, Seugyoon Lee, Naksoon Kim. A parametric study on forming length in roll forming[J]. Materials Processing Technology, 2001, (113):774-778
[20]M Kiuchi,F Wang.FEM Simulation of roll forming of ERW pipes and mill/process design. Proceedings of the ICTP, Sept, 1999:19-24
[21]赵金龙.大型方矩形管直接成型的仿真研究[硕士学位论文].北京：北方工业大学,2008
[22]Nitin,Duggal,Taylan. Computer Aided Simulation of Cold Roll Forming-Computer Program for Simple Section Profiles. Material Processing Technology, 1996, (59): 41-48
[23]г.я.古恩.金属压力加工理论基础[M].北京：冶金工业出版社,1989.
[24]M.Lindgren. Cold roll forming of a U-channel made of high strength steel[J]. Journal of Materials Processing Technology, 2007, (2):78-81
[25]A. Alsamhan, P. Hartely, I. Pillinger. The computer simulation of cold-roll-forming using FE methods and applied real time re-meshing techniques[J]. Journal of Materials Processing Technology,2003, (142):102-111
[26]Kim Naksoo, Kang Byungseok, Lee Seungyoon. Prediction and design of edge shape of initial strip for thick tube roll forming using finite element method[J]. Journal of Materials Processing Technology,2003(142):479-486
[27]S D Zhu, S M Panton, J L Duncan. The effects of geometric variables in roll forming a channel section[J]. Journal of Engineering Manufacture, 1996, (210):27-134
[28]D Bhattacharyya,P D Smith. The Prediction of deformation length in cold roll-forming[J]. Journal of Mechanical Working Technology,1984.9 (9):181-191
[29]刘向东,申屠留芳,徐其文.冷弯型钢成型辊上压力分析计算[J].淮海工学院学报,1996,(2)：20～26
[30]崔高健,赵璞,陈嘉鹏.槽钢辊式冷弯成型孔型设计[J].机械,2006,(10)：14-17
[31]崔高建,迟正洪,吕相艳.冷弯型钢槽型钢辊弯成型过程计算[J].研究探讨,2006,(4)：55-56
[32]刘向东,高丽华,王成轩.冷弯型钢临界弯曲半径的影响因素分析[J].机械工程师,1999,(2)：6-7
[33]Senanayake.R.S, Cole.I.M, Thiruvarudchelvan S. The Application of Computationaland Experimental Techniques to Metal Deformation in Cold Roll forming[JJ. J.Mater.Process.Tech, 1994,45(4):155-160
[34]Rusz S. Hot deformation resistance models based on the rolling forces measure-ment, Acta Metallurgica Slovaca, 2005,11, 265-266
[35]S.M. Pantona, S.D.Zhua,J.L. Duncana. Fundamental deformation types and sectional properties in roll forming[J]. International Journal of Mechanical Sciences, 1994,36(8):725-735
[36]S. M. Pantona, J. L. Duncana, S. D. Zhu. Longitudinal and shear strain development in cold roll forming[J]. Journal of Materials Processing Technology, 1996, 60(3):219-224
[37]D.Bhattacharyya, R.J.Dykes, P.j.Hunter. Analysis of Roll Forming Continuous Fibre-reinforced Thermoplastic Sheets [J]. Journal of Engineering Manufacture, 1999, (2), 235-255
[38]Farzin, M., M.S. Tehrani, E. Shameli, Determination of buckling limit of strain in cold roll forming by the finite element analysis [J]. Journal of Materials Processing Technology, 2002, (125):626-632
[39]Han, Z.W. Modelling of cold roll forming of steel strip[J]. Materials Science and Technology, 2001,17(4): 415-418.
[40]M. Farzin, M.S. Tehrani, E. Shameli. Determination of buckling limit of strain in cold roll forming by finite element analysis[J]. J. Mater. Process.Technol. 2002, (125):626-632
[41]C,K. McClure, H.Li. Roll forming simulation using finite-element analysis[J]. J. Manuf.Rev,2000, (15):56-61
[42]M.Tajdari,M.Farzin. Numerical analysis of cold roll forming of symmetrical open sections[J]. J.Mater.Process.Technol,2002, (125):633-637
[43]Zhang Lele, Tan Nan lin. Visual simulation of cold roll-forming based on object oriented programming[J]. Journal of Engineering Mechanics, 2004, 17(1):70-72
[44]Brunet M, Lay B. Computer Aided Design of Roll Forming of Channel Section[J]. Journalof Materials Processing Technology, 1996, 60: 209-214
[45]Nitin Duggal. Process simulation of roll forming and roll pass design[D].The Degree Master of Science in the Graduate School of the Ohio State University, 1995, 1-22
[46]McClure, C.K.a.L. Roll forming simulation using finite element analysis[J]. Manufacturing Review, 1995, 8: 114-115
[47]Y. Kong, Y. Sun, X. Wang. Development of new friction test device in sheet forming, in: A. Altan (Ed.), Proceedings of the Fifth ICTP, 1996, (2):835-838.
[48]高丽华,王成轩.影响冷弯型槽钢腿部成型辊上最大压力因素综合分析[J].机械研究与应用,2000,(13：9-15
[49]张乐乐,谭南林,刘才.冷弯成形过程的样条有限条方法仿真与应用[J].系统仿真学,2008,(97)：1703～1706
[50]D. Bhattacharyya, P.D. Smith, C.H. Yee, L.F. Collins. The prediction of deformation length in cold roll forming[J]. J. Mech. Work. Tech.1984, (9):181-191
[51]Alexander S. Galakhar, Paul A. Meehan, William J.T. Daniel, and Shi Chao Ding. A method of approximate tool wear analysis in cold roll forming 5th Australasian[C]//. Congress on Applied Mechanics, ACAM 2007
[52]小奈弘,刘继英.冷弯成型技术[M].北京：化学工业出版社,2008
[2]王春新,刘继英.冷弯成形过程仿真技术的发展[J].北方工业大学学报,2004,16(1)：46～50
[3]韩志武,刘才,陆卫平.辊弯成型工艺、理论及CAE技术研究进展与展望[J].钢铁,1999,34(7)：70～76
[4]K Nakajima, W Miznutani et, al. Development of new vertical roll forming process for ERW pipe. Nippon Steel Technical Report, 1980, 8(15):127-144
[5]Terrt R Walker, Roy J Pick. Approximation of the Axial Strains Developed During the Roll Forming of Pipe. J. Mater. Process. Technol, 1990, 22:29-44
[7]崔高健,吕相艳,迟正洪.冷弯型钢成型技术的发展现状[J].机械制造,2005,43(494)：41-44
[8]赵璞.基于有限元数值模拟的不锈钢冷弯成型扭曲的研究[硕士学位论文].长春：长春工业大学,2007
[9]Alexander S. Galakhar, Paul A. Meehan, William J.T. Daniel, and Shi Chao Ding. A method of approximate tool wear analysis in cold roll forming 5th Australasian[C]//. Congress on Applied Mechanics, ACAM 2007
[10]习荣堂,李景方.冷弯成型过程中变形过渡区的研究[J].东北大学学报,16(6)：593-597
[11]李景芳,习荣堂.冷弯型钢成型力能参数研究[J].《重型机械》,1994(1)：47-50
[12]习荣堂,李景方,樊永义.冷弯成型力研究[J].东北大学学报,1996,17(1)：94-97
[13]樊永义,杨莅彦.冷弯槽钢变形过渡区长度的计算[J].冶金设备,2000,(5)：1-5
[14]丁国良.冷弯型钢中力能参数的理论推导[C]//.2005中国国际冷弯型钢研讨会论文集,2005,1～10
[15]兑关锁.冷弯型钢纵向变形的理论分析及计算[J].钢铁研究学报,1997,(2)：1-3
[16]岳崇锋,余万华,冯光宏.冷弯成型技术研究现状[C]//.第六届华北(扩大)塑性加工学术年会论文集,北京：北京科技大学,2009,44-49
[17]陈锡栋,杨婕,赵晓栋等.有限元法的发展现状及应用[J]；中国制造业信息化,2010,11：6-8
[18]马航.板带矫正机的模拟研究[硕士学位论文].武汉：武汉科技大学,2010
[19]] Sukmoo Hong, Seugyoon Lee, Naksoon Kim. A parametric study on forming length in roll forming[J]. Materials Processing Technology, 2001, (113):774-778
[20]M Kiuchi,F Wang.FEM Simulation of roll forming of ERW pipes and mill/process design. Proceedings of the ICTP, Sept, 1999:19-24
[21]赵金龙.大型方矩形管直接成型的仿真研究[硕士学位论文].北京：北方工业大学,2008
[22]Nitin,Duggal,Taylan. Computer Aided Simulation of Cold Roll Forming-Computer Program for Simple Section Profiles. Material Processing Technology, 1996, (59): 41-48
[23]г.я.古恩.金属压力加工理论基础[M].北京：冶金工业出版社,1989.
[24]M.Lindgren. Cold roll forming of a U-channel made of high strength steel[J]. Journal of Materials Processing Technology, 2007, (2):78-81
[25]A. Alsamhan, P. Hartely, I. Pillinger. The computer simulation of cold-roll-forming using FE methods and applied real time re-meshing techniques[J]. Journal of Materials Processing Technology,2003, (142):102-111
[26]Kim Naksoo, Kang Byungseok, Lee Seungyoon. Prediction and design of edge shape of initial strip for thick tube roll forming using finite element method[J]. Journal of Materials Processing Technology,2003(142):479-486
[27]S D Zhu, S M Panton, J L Duncan. The effects of geometric variables in roll forming a channel section[J]. Journal of Engineering Manufacture, 1996, (210):27-134
[28]D Bhattacharyya,P D Smith. The Prediction of deformation length in cold roll-forming[J]. Journal of Mechanical Working Technology,1984.9 (9):181-191
[29]刘向东,申屠留芳,徐其文.冷弯型钢成型辊上压力分析计算[J].淮海工学院学报,1996,(2)：20～26
[30]崔高健,赵璞,陈嘉鹏.槽钢辊式冷弯成型孔型设计[J].机械,2006,(10)：14-17
[31]崔高建,迟正洪,吕相艳.冷弯型钢槽型钢辊弯成型过程计算[J].研究探讨,2006,(4)：55-56
[32]刘向东,高丽华,王成轩.冷弯型钢临界弯曲半径的影响因素分析[J].机械工程师,1999,(2)：6-7
[33]Senanayake.R.S, Cole.I.M, Thiruvarudchelvan S. The Application of Computationaland Experimental Techniques to Metal Deformation in Cold Roll forming[JJ. J.Mater.Process.Tech, 1994,45(4):155-160
[34]Rusz S. Hot deformation resistance models based on the rolling forces measure-ment, Acta Metallurgica Slovaca, 2005,11, 265-266
[35]S.M. Pantona, S.D.Zhua,J.L. Duncana. Fundamental deformation types and sectional properties in roll forming[J]. International Journal of Mechanical Sciences, 1994,36(8):725-735
[36]S. M. Pantona, J. L. Duncana, S. D. Zhu. Longitudinal and shear strain development in cold roll forming[J]. Journal of Materials Processing Technology, 1996, 60(3):219-224
[37]D.Bhattacharyya, R.J.Dykes, P.j.Hunter. Analysis of Roll Forming Continuous Fibre-reinforced Thermoplastic Sheets [J]. Journal of Engineering Manufacture, 1999, (2), 235-255
[38]Farzin, M., M.S. Tehrani, E. Shameli, Determination of buckling limit of strain in cold roll forming by the finite element analysis [J]. Journal of Materials Processing Technology, 2002, (125):626-632
[39]Han, Z.W. Modelling of cold roll forming of steel strip[J]. Materials Science and Technology, 2001,17(4): 415-418.
[40]M. Farzin, M.S. Tehrani, E. Shameli. Determination of buckling limit of strain in cold roll forming by finite element analysis[J]. J. Mater. Process.Technol. 2002, (125):626-632
[41]C,K. McClure, H.Li. Roll forming simulation using finite-element analysis[J]. J. Manuf.Rev,2000, (15):56-61
[42]M.Tajdari,M.Farzin. Numerical analysis of cold roll forming of symmetrical open sections[J]. J.Mater.Process.Technol,2002, (125):633-637
[43]Zhang Lele, Tan Nan lin. Visual simulation of cold roll-forming based on object oriented programming[J]. Journal of Engineering Mechanics, 2004, 17(1):70-72
[44]Brunet M, Lay B. Computer Aided Design of Roll Forming of Channel Section[J]. Journalof Materials Processing Technology, 1996, 60: 209-214
[45]Nitin Duggal. Process simulation of roll forming and roll pass design[D].The Degree Master of Science in the Graduate School of the Ohio State University, 1995, 1-22
[46]McClure, C.K.a.L. Roll forming simulation using finite element analysis[J]. Manufacturing Review, 1995, 8: 114-115
[47]Y. Kong, Y. Sun, X. Wang. Development of new friction test device in sheet forming, in: A. Altan (Ed.), Proceedings of the Fifth ICTP, 1996, (2):835-838.
[48]高丽华,王成轩.影响冷弯型槽钢腿部成型辊上最大压力因素综合分析[J].机械研究与应用,2000,(13：9-15
[49]张乐乐,谭南林,刘才.冷弯成形过程的样条有限条方法仿真与应用[J].系统仿真学,2008,(97)：1703～1706
[50]D. Bhattacharyya, P.D. Smith, C.H. Yee, L.F. Collins. The prediction of deformation length in cold roll forming[J]. J. Mech. Work. Tech.1984, (9):181-191
[51]Alexander S. Galakhar, Paul A. Meehan, William J.T. Daniel, and Shi Chao Ding. A method of approximate tool wear analysis in cold roll forming 5th Australasian[C]//. Congress on Applied Mechanics, ACAM 2007
[52]小奈弘,刘继英.冷弯成型技术[M].北京：化学工业出版社,2008