槽钢辊弯成型的数值模拟及工艺参数研究
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摘要
槽钢是一种经济断面型材，广泛应用于汽车、航空、轻工、机械制造以及建筑等各个行业。槽钢的成型过程是非常复杂的，其变形是横向弯曲、纵向拉伸及横向剪切等多种变形的组合，其复杂性主要表现在几何、材料和接触边界等多重非线性，而且影响成型因素众多，精确模拟其成型过程是比较困难的。目前，国内外学者对此还没有提出一种成熟精确的分析方法。生产中的工艺设计和孔型设计仍然主要取决于经验知识。
本文首先介绍了国内外关于辊式冷弯成型理论研究的现状与发展趋势，并比较了各成型理论的优缺点，随后在分析槽钢辊弯成型特点及其变形规律的基础上，以弹塑性大变形有限元理论为基础，对槽钢成型过程做出合理简化，建立分析模型，利用MARC软件对槽钢辊弯成型进行了三维有限元数值模拟分析。得出了槽钢在成形过程中变形区应力、应变的分布规律以及各道次的几何变形情况。对在不同成型底线和道次等工艺参数下的板坯应力、应变分布情况进行了对比分析，并探讨了这些工艺参数对槽钢成型的影响。
论文将计算结果与相关试验结果进行了比较，验证了模拟方法的有效性和可靠性及计算结果的正确性。为今后冷弯槽钢CAD系统提供了可靠的预测模型和成形验证模型，为实际生产应用提供了直接依据，具有理论意义和应用价值。
Channel section steel is a kind of economic cross section steel, the products are widely used in automobile, aviation, light industry, machinery manufacture and construction areas. The roll forming is a very complex process, in which the deformation is a combination of several deformations including lateral bending, longitudinal tensile and lateral shear deformation, et al. It includes not only the deformation process with geometric nonlinearity, material nonlinearity and contact boundary nonlinearity, but also so many effects on its forming process, so it is a quite difficult task to simulate this process precisely. Nowadays, nobody has presented a kind of very perfect and precise analysis method in the world. The design of pass schedules and roll profiles mainly remains more an art than a science.
Firstly, this paper introduce the present and prospective development, moreover compared advantage and short of different roll forming theory. Subsequently simplified process and analyzable model of channel section according to deforming elastic-plastic macro deforming finite element theory. MARC is used to predict stress and strain distributions predicted by simulations, at the same time, the deformation of sheet geometry can also be simulated during and after the process. At last, the general regulation of various forming parameters' effects on the channel section is obtained.
The forming process of the channel is simulated successfully and the results coincide with experimental result in relational document. The validity of this model is proved further. The work provides a reliable prediction model for cold roll forming CAD system in future, so it supplies practical production with a valuable reference.
本文首先介绍了国内外关于辊式冷弯成型理论研究的现状与发展趋势，并比较了各成型理论的优缺点，随后在分析槽钢辊弯成型特点及其变形规律的基础上，以弹塑性大变形有限元理论为基础，对槽钢成型过程做出合理简化，建立分析模型，利用MARC软件对槽钢辊弯成型进行了三维有限元数值模拟分析。得出了槽钢在成形过程中变形区应力、应变的分布规律以及各道次的几何变形情况。对在不同成型底线和道次等工艺参数下的板坯应力、应变分布情况进行了对比分析，并探讨了这些工艺参数对槽钢成型的影响。
论文将计算结果与相关试验结果进行了比较，验证了模拟方法的有效性和可靠性及计算结果的正确性。为今后冷弯槽钢CAD系统提供了可靠的预测模型和成形验证模型，为实际生产应用提供了直接依据，具有理论意义和应用价值。
Channel section steel is a kind of economic cross section steel, the products are widely used in automobile, aviation, light industry, machinery manufacture and construction areas. The roll forming is a very complex process, in which the deformation is a combination of several deformations including lateral bending, longitudinal tensile and lateral shear deformation, et al. It includes not only the deformation process with geometric nonlinearity, material nonlinearity and contact boundary nonlinearity, but also so many effects on its forming process, so it is a quite difficult task to simulate this process precisely. Nowadays, nobody has presented a kind of very perfect and precise analysis method in the world. The design of pass schedules and roll profiles mainly remains more an art than a science.
Firstly, this paper introduce the present and prospective development, moreover compared advantage and short of different roll forming theory. Subsequently simplified process and analyzable model of channel section according to deforming elastic-plastic macro deforming finite element theory. MARC is used to predict stress and strain distributions predicted by simulations, at the same time, the deformation of sheet geometry can also be simulated during and after the process. At last, the general regulation of various forming parameters' effects on the channel section is obtained.
The forming process of the channel is simulated successfully and the results coincide with experimental result in relational document. The validity of this model is proved further. The work provides a reliable prediction model for cold roll forming CAD system in future, so it supplies practical production with a valuable reference.
引文
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2 林时宪.国外冷弯型钢.北京:冶金工业出版社,1984:382-386 1-2 66-67
3 K. Sweeney, U. Grunewald. The Application of Roll Forming for Automotive Structural Parts. J. Mater. Process. Tech, 2003, 132: 9-15
4 王先进, 石京.国内外冷弯型钢研究的最新进展.轧钢,1998,5:24-28
5 B. N. 达维多夫, Mл.马科萨柯夫.薄壁冷弯型钢生产.穆东生.北京:中国机械工业出版社,1962:5-8 93-96
6 R. J. Dyke, S. J. Mander, D. Bhattacharyya. Roll Forming Continuous Fiber-reinforcedThermoplastic Sheets: Expereimental Analysis. The Second Australasian Conference on Materials, Seoul, 2000, 31: 1395-1407
7 Frank Heislitz, Haydar Livatyali, Mustafa A.Ahmetoglu, et al. Simulation of RollForming Process With the 3-D FEM Code PAM-STAMP. J. Mater. Process. Tech, 1996, 59: 59-67
8 刘继英.冷弯型钢CAD/CAM的一体化技术.北方工业大学学报,1996,8(3):17-20
9 D. Bhattacharyya, S. M. Paton. 冷辊成型的研究及计算机辅助辊型设计.钢管,
1989,2:23-29
10 杨继峰.我国直缝焊管成型技术的进展.钢管,1997,26(2):12-19
11 徐尚义.现代辊式冷弯成型生产技术的新发展.焊管,1994,27(6):6-11
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13 曲贵良, 宋蓉华.CTA焊管技术.焊管,1997,20(1):52-55
14 官方立.FF轧制技术的开发和进展.焊管,1996,19(4):49-60
15 胡松林.直缝焊管变形工艺的发展越势.焊管,1994,17(1):10-13
16 冯世功.排辊成型(Cage Roll Forming Process).焊管,1994,17(6):55-57
17 冯世功.简谈现代化ERW焊管成型机.焊管,1991,14(5):35-41
18 韩志武, 刘才, 路卫平, 等.辊弯成型的工艺、理论及CAE技术研究进展与展望.钢铁, 1999,34(7):70-72
19 加藤健三.冷间ロール成形.日刊工业新闻, 1975,21-23
20 小奈弘, 神马敬.塑性と加工,1983,24:270
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21 and its Influence on Product Straightness. 1st Int. Con. on Technology of
Plasticity, Toyota, 1985: 423-436
22 樊永义, 杨莅彦.冷弯槽钢变形过渡区长度的计算.冶金设备,2000,5:1-5
23 K. Nakajima, W. Miznutani. Development of New Vertical Roll Forming Process for ERW pipe. Nippon Steel Technical Report. 1980, 12: 127-144
24 T. R. Walker and R. J. Pick. Approximation of the Axial Strain Developed
During the Roll Forming of ERW Pipe. J. Mater. Process. Tech, 1990, 22: 29-44
25 T. R. walker and R. J. Pick. Developments in the Geometric Modeling of an ERW Pipe Schlep. J. Mater. Process. Tech, 1991, 25: 35-54
26 Г.Я.古思.金属压力加工理论基础.赵志业, 王国栋.北京:冶金工业出版社,1989:66-70
27 木内学, 高田桥俊夫.型材のロールフォーヾソグ加工のシミュレーショソ.塑性と加工,1986,27:874-881
28 花江, 木内学.带材辊型的计算机仿真模型研究.钢铁,1996,31(3):43-45
29 木内学, 高田桥俊夫.型材のロールフォーヾソグ加工のシミュレーショソ.塑性と加工,1986,27:1091-1098
30 木内学, 高田桥俊夫.ロールフラワーの自动设计システㄙの应用.塑性と加工,1987,28(312):49-57
31 李国忠.冷弯型钢辊型计算机辅助设计系统的建立与研究.[北京钢铁学院硕士学位论文].1987:40-45
32 曹志远.非线性弹性有限条分析.上海力学,1992,13(1):27-31
33 刘人怀.板壳非弹性力学研究的最新进展.上海力学.1989,10:3
34 林振波.冷带轧机板形判别模型的有限条分析.[燕山大学博士论文].1993:41-46
35 韩志武, 刘才, 陆卫平, 等.工艺参数对简单断面型钢辊弯成型过程的影响.金属学报,2002,38(3):331-333
36 Liu C, Zhou Y, Lu W. Numerical Simulation of Roll-forming by B-spline Finite Strip Method. J. Mater. Process. Tech, 1996, 60: 215-218
37 韩志武, 刘才.外卷边槽钢辊弯成型过程数值模拟.应用数学和力学, 2002,23(3)292-298
38 张乐乐, 刘才, 张华弟, 等.基于样条有限条法的冷弯成型全流层模拟.钢铁研究学报,2002,14(3):19-24
39 韩志武, 刘才.薄板结构弹塑性大挠度样条有限条分析.兵工学报,
2002,23(1):94-97
40 Cheung M. S, Ng S. F. Finite Strip Analysis of Beams and Plates with Material Nonlinearity. Computers & Structures, 1989, 33(1): 289-294
41 周瑛.辊式成型过程的弹塑性大变形样条有限条模拟.[燕山大学博士学位论 文].1996:36-49
42 韩志武.基于大变形有限条法的冷弯成型计算机模拟与专家系统技术的研究.[燕山大学博士学位论文].1998:12-32
43 王守仪.有限元法教程.哈尔滨:哈尔滨工业大学出版社,1994:35-47
44 王勖成，邵敏.有限元单元法基本原理和数值方法.北京:清华大学出版社.1997:15-59
45 谢水生，王祖唐.金属塑性成形工步的有限元数值模拟.北京:冶金工业出版社,1997:1-12
46 刘才.金属成型非线性有限元模拟技术.燕山大学学报,1998,22(1):23-26
47 但文蛟, 王耕, 张树根, 等.板料成形CAE技术.模具技术,2002,(3):37-9
48 Perzyna, P. Fundamental Problems in Viso-Plasticity in Relent Advance in Applied Mechanies. New York. Acamie Press, 1966: 43-277
49 S. M, Duncan. J. L, Zhu. S. D. Longitudinal and Shear Stain Development in Cold Roll Forming. J. Mater. Process. Tech, 1996, 60: 219-224
50 Heislitz. F, Livatyail. H, Ahmetoglu. M. A. Simulation of Roll Forming Process with the 3-D FEM Code PAM-STAMP. J. Mater. Process. Tech, 1996, 59: 59-67
51 Senanayake. R. S, Cole. I .M, Thiruvarudchelvan S. The Application of Computationaland Experimental Techniques to Metal Deformation in Cold Roll forming. J. Mater.Process. Tech, 1994, 45: 155-160
52 M. Tajdari, M. Farzin, Simulation of Cold Roll Forming of Channel SectionsProceedings of the First WMC International Symposium on Manufacturing Systems, Auckland, New Zland, 1997: 311-317
53 M. Tajdri, M. Farzin. Numerical Analysis of Cool Forming of Symmetrical OpenSections. J. Mater. Process. Tech, 2002, 125: 633-637
54 小野田义富, 川井彰.电缝管のWベンド成形およびUべンド成形における素板の变形特性の有限要素シミユレ シヨン. 塑性と加工, 1993,34(395):1358-1363.
55 Nitin, Duggal, Taylan A. ltan. Computer Aided Simulation of Cold Roll Forming- Computer Program for Simple Section Profiles. J. Mater. Process. Technol, 1996, 59: 41-48
56 M. Brunet. A Finite Element Method for Unilateral Contact and Friction Problem involving Finite Strain and Large Displacement, Journal of Theoretical and Applied Mech, 1988, 7: 209-220
57 M. Brunet. Some Computational Aspects in Three Dimensional and Plane Stress Finite Elastoplastic Deformation Problem. Engineering Analysis with Boundary Element, 1989, 6: 78-83
58 M. Brunet, B. lay, P. Pol. computer Aided Design of Roll-Forming of Channel Sections.
J. Mater. Process. Tech, 1996, 60: 209-214
59 Liu C, Zhou Y, Lu W. Numerical Simulation of Roll Forming for Channel Section with Outer Edge. Applied Mathematics and Mechanics, 2002, 23(3): 321-328
60 徐树成, 刘才.方矩形管第一道次辊弯成形过程的变形和应力场.燕山大学学报, 2000, 24(1):15-18
61 韩志武, 刘才.冷弯成型数值模拟与孔型CAD集成.钢铁,2001,36(7):30-33
62 张忠林.多品种冷弯型钢DLW-CAD软件系统的研制与开发.[燕山大学工学硕士论文].1997:24
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69 K. Damn, Determination of Longitudinal Strains in Roll-Forming of Standard Sections in a Multi-Stand Machine, Dissertation, Institute for Production Technology, University of Darmstadt, Germany, 1989: 26-49
2 林时宪.国外冷弯型钢.北京:冶金工业出版社,1984:382-386 1-2 66-67
3 K. Sweeney, U. Grunewald. The Application of Roll Forming for Automotive Structural Parts. J. Mater. Process. Tech, 2003, 132: 9-15
4 王先进, 石京.国内外冷弯型钢研究的最新进展.轧钢,1998,5:24-28
5 B. N. 达维多夫, Mл.马科萨柯夫.薄壁冷弯型钢生产.穆东生.北京:中国机械工业出版社,1962:5-8 93-96
6 R. J. Dyke, S. J. Mander, D. Bhattacharyya. Roll Forming Continuous Fiber-reinforcedThermoplastic Sheets: Expereimental Analysis. The Second Australasian Conference on Materials, Seoul, 2000, 31: 1395-1407
7 Frank Heislitz, Haydar Livatyali, Mustafa A.Ahmetoglu, et al. Simulation of RollForming Process With the 3-D FEM Code PAM-STAMP. J. Mater. Process. Tech, 1996, 59: 59-67
8 刘继英.冷弯型钢CAD/CAM的一体化技术.北方工业大学学报,1996,8(3):17-20
9 D. Bhattacharyya, S. M. Paton. 冷辊成型的研究及计算机辅助辊型设计.钢管,
1989,2:23-29
10 杨继峰.我国直缝焊管成型技术的进展.钢管,1997,26(2):12-19
11 徐尚义.现代辊式冷弯成型生产技术的新发展.焊管,1994,27(6):6-11
12 王大齐.辊弯成型新工艺.上海金属,1996,18(1):30-33
13 曲贵良, 宋蓉华.CTA焊管技术.焊管,1997,20(1):52-55
14 官方立.FF轧制技术的开发和进展.焊管,1996,19(4):49-60
15 胡松林.直缝焊管变形工艺的发展越势.焊管,1994,17(1):10-13
16 冯世功.排辊成型(Cage Roll Forming Process).焊管,1994,17(6):55-57
17 冯世功.简谈现代化ERW焊管成型机.焊管,1991,14(5):35-41
18 韩志武, 刘才, 路卫平, 等.辊弯成型的工艺、理论及CAE技术研究进展与展望.钢铁, 1999,34(7):70-72
19 加藤健三.冷间ロール成形.日刊工业新闻, 1975,21-23
20 小奈弘, 神马敬.塑性と加工,1983,24:270
D. Bhattacharyya, et al. The Development of Longitudinal Strain in Cold Roll Forming
21 and its Influence on Product Straightness. 1st Int. Con. on Technology of
Plasticity, Toyota, 1985: 423-436
22 樊永义, 杨莅彦.冷弯槽钢变形过渡区长度的计算.冶金设备,2000,5:1-5
23 K. Nakajima, W. Miznutani. Development of New Vertical Roll Forming Process for ERW pipe. Nippon Steel Technical Report. 1980, 12: 127-144
24 T. R. Walker and R. J. Pick. Approximation of the Axial Strain Developed
During the Roll Forming of ERW Pipe. J. Mater. Process. Tech, 1990, 22: 29-44
25 T. R. walker and R. J. Pick. Developments in the Geometric Modeling of an ERW Pipe Schlep. J. Mater. Process. Tech, 1991, 25: 35-54
26 Г.Я.古思.金属压力加工理论基础.赵志业, 王国栋.北京:冶金工业出版社,1989:66-70
27 木内学, 高田桥俊夫.型材のロールフォーヾソグ加工のシミュレーショソ.塑性と加工,1986,27:874-881
28 花江, 木内学.带材辊型的计算机仿真模型研究.钢铁,1996,31(3):43-45
29 木内学, 高田桥俊夫.型材のロールフォーヾソグ加工のシミュレーショソ.塑性と加工,1986,27:1091-1098
30 木内学, 高田桥俊夫.ロールフラワーの自动设计システㄙの应用.塑性と加工,1987,28(312):49-57
31 李国忠.冷弯型钢辊型计算机辅助设计系统的建立与研究.[北京钢铁学院硕士学位论文].1987:40-45
32 曹志远.非线性弹性有限条分析.上海力学,1992,13(1):27-31
33 刘人怀.板壳非弹性力学研究的最新进展.上海力学.1989,10:3
34 林振波.冷带轧机板形判别模型的有限条分析.[燕山大学博士论文].1993:41-46
35 韩志武, 刘才, 陆卫平, 等.工艺参数对简单断面型钢辊弯成型过程的影响.金属学报,2002,38(3):331-333
36 Liu C, Zhou Y, Lu W. Numerical Simulation of Roll-forming by B-spline Finite Strip Method. J. Mater. Process. Tech, 1996, 60: 215-218
37 韩志武, 刘才.外卷边槽钢辊弯成型过程数值模拟.应用数学和力学, 2002,23(3)292-298
38 张乐乐, 刘才, 张华弟, 等.基于样条有限条法的冷弯成型全流层模拟.钢铁研究学报,2002,14(3):19-24
39 韩志武, 刘才.薄板结构弹塑性大挠度样条有限条分析.兵工学报,
2002,23(1):94-97
40 Cheung M. S, Ng S. F. Finite Strip Analysis of Beams and Plates with Material Nonlinearity. Computers & Structures, 1989, 33(1): 289-294
41 周瑛.辊式成型过程的弹塑性大变形样条有限条模拟.[燕山大学博士学位论 文].1996:36-49
42 韩志武.基于大变形有限条法的冷弯成型计算机模拟与专家系统技术的研究.[燕山大学博士学位论文].1998:12-32
43 王守仪.有限元法教程.哈尔滨:哈尔滨工业大学出版社,1994:35-47
44 王勖成，邵敏.有限元单元法基本原理和数值方法.北京:清华大学出版社.1997:15-59
45 谢水生，王祖唐.金属塑性成形工步的有限元数值模拟.北京:冶金工业出版社,1997:1-12
46 刘才.金属成型非线性有限元模拟技术.燕山大学学报,1998,22(1):23-26
47 但文蛟, 王耕, 张树根, 等.板料成形CAE技术.模具技术,2002,(3):37-9
48 Perzyna, P. Fundamental Problems in Viso-Plasticity in Relent Advance in Applied Mechanies. New York. Acamie Press, 1966: 43-277
49 S. M, Duncan. J. L, Zhu. S. D. Longitudinal and Shear Stain Development in Cold Roll Forming. J. Mater. Process. Tech, 1996, 60: 219-224
50 Heislitz. F, Livatyail. H, Ahmetoglu. M. A. Simulation of Roll Forming Process with the 3-D FEM Code PAM-STAMP. J. Mater. Process. Tech, 1996, 59: 59-67
51 Senanayake. R. S, Cole. I .M, Thiruvarudchelvan S. The Application of Computationaland Experimental Techniques to Metal Deformation in Cold Roll forming. J. Mater.Process. Tech, 1994, 45: 155-160
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53 M. Tajdri, M. Farzin. Numerical Analysis of Cool Forming of Symmetrical OpenSections. J. Mater. Process. Tech, 2002, 125: 633-637
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