板料拉深过程中的摩擦模型及其有限元模拟研究
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摘要
摩擦与润滑状态是影响金属板料成形工艺的一个重要因素,因此在数值模拟过程中,为了获得更加准确的模拟结果,就必须对板料成形过程中的摩擦行为进行准确的描述。而要达到此目的,就需要更加符合实际的摩擦模型以及利用软件的二次开发功能对摩擦模型进行二次开发,并将其应用于模拟过程中。
1)基于摩擦学理论和金属塑性加工理论,建立了流体润滑条件下轴对称件拉深成形过程中摩擦阻力与表面粗糙度、润滑剂及相对滑动速度等之间的关系模型。
2)分析了板料拉深成形过程中不同区域的摩擦行为及其对应的摩擦模型。
3)对ABAQUS软件的子程序二次开发进行了分析,根据模具与板料之间的动态接触状态的变化及不同的区域采用不同的摩擦模型,编写了相应子程序。
4)设计制作了一模拟实验系统,探讨了板料拉深成形过程中摩擦状态的变化规律。而且还利用了探针摩擦测试装置对盒形件拉深成形过程摩擦系数进行了测试。
5)利用ABAQUS/Explicit有限元分析软件,将所编的摩擦模型二次开发子程序应用于圆筒件拉深和盒形件拉深过程有限元模拟,并矩形盒形件模拟结果与其探针摩擦系数测试实验结果进行了对比,结果表明应用本文中的摩擦模型及二次开发子程序的正确性及可行性。
The friction and lubrication status is a very important factor that influences the sheet metal forming. To gain more accurate analog result, the friction behaviors should be described well and truly in the sheet forming simulation system. And to attain this purpose, the more accurate friction model and the user subroutine of the friction model should be applied in the simulation system.1)Studying friction behaviors in sheet metal forming process, the author established the friction models of full film lubrication and mixed lubrication according to the ratio between the film thickness and the surface roughness of die and sheet blank.2)This paper have studied the friction behaviors in deep drawing and the friction model in different region of die and sheet blank.3)In the paper, the ABAQUS software and the user subroutine have been studied. Furthermore, the programs of the friction models have been second exploited based on the VFRIC and the different friction models.4) In the end, in order to test and investigate the dynamic variation of friction in experimental approach, the author developed a experimental system based on the existing condition. And, the laws of friction coefficient variation with the forming parameters are determined based on the experimental system and tribotest system developed by the Shanghai Jiao Tong University.5)A three-dimension finite element model by the ABAQUS/Explicit software for analyzing the effect of friction in deep drawing has been developed based on both tribological and metal processing theories. In the last,the simulation results has been compared with the experiment results, which show the friction models are right.
1)基于摩擦学理论和金属塑性加工理论,建立了流体润滑条件下轴对称件拉深成形过程中摩擦阻力与表面粗糙度、润滑剂及相对滑动速度等之间的关系模型。
2)分析了板料拉深成形过程中不同区域的摩擦行为及其对应的摩擦模型。
3)对ABAQUS软件的子程序二次开发进行了分析,根据模具与板料之间的动态接触状态的变化及不同的区域采用不同的摩擦模型,编写了相应子程序。
4)设计制作了一模拟实验系统,探讨了板料拉深成形过程中摩擦状态的变化规律。而且还利用了探针摩擦测试装置对盒形件拉深成形过程摩擦系数进行了测试。
5)利用ABAQUS/Explicit有限元分析软件,将所编的摩擦模型二次开发子程序应用于圆筒件拉深和盒形件拉深过程有限元模拟,并矩形盒形件模拟结果与其探针摩擦系数测试实验结果进行了对比,结果表明应用本文中的摩擦模型及二次开发子程序的正确性及可行性。
The friction and lubrication status is a very important factor that influences the sheet metal forming. To gain more accurate analog result, the friction behaviors should be described well and truly in the sheet forming simulation system. And to attain this purpose, the more accurate friction model and the user subroutine of the friction model should be applied in the simulation system.1)Studying friction behaviors in sheet metal forming process, the author established the friction models of full film lubrication and mixed lubrication according to the ratio between the film thickness and the surface roughness of die and sheet blank.2)This paper have studied the friction behaviors in deep drawing and the friction model in different region of die and sheet blank.3)In the paper, the ABAQUS software and the user subroutine have been studied. Furthermore, the programs of the friction models have been second exploited based on the VFRIC and the different friction models.4) In the end, in order to test and investigate the dynamic variation of friction in experimental approach, the author developed a experimental system based on the existing condition. And, the laws of friction coefficient variation with the forming parameters are determined based on the experimental system and tribotest system developed by the Shanghai Jiao Tong University.5)A three-dimension finite element model by the ABAQUS/Explicit software for analyzing the effect of friction in deep drawing has been developed based on both tribological and metal processing theories. In the last,the simulation results has been compared with the experiment results, which show the friction models are right.
引文
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[3] 印雄飞,阮雪榆:板料成形过程的数值模拟技术[J],塑性工程学报,1999.3.NO.1
[4] 镜星,印雄飞:板料成形过程的数值模拟技术[J],模具技术,1998.NO.4
[5] 肖景容,姜奎华:冲压工艺学,机械工业出版社,1999.5.NO.1
[6] 赵军,马瑞:板材成形新技术及其发展趋势(1) [J],金属成形工艺,2002,20(6):1-5
[7] 罗亚军,杨曦,何丹农,张永清:板料成形中的有限元数值模拟技术[J],金属成形工艺,2000.NO.6
[8] 郑莹,吴勇国,李尚键,李志刚,肖景容:板料成形数值模拟进展[J],塑性工程学报,1996.12
[9] 熊火轮:计算机辅助板料成形分析模拟系统,北京航空航天大学博士学位论文,1990
[10] 董湘怀:轴对称及三维金属板料成形过程的有限元模拟,华中理工大学博士学位论文,1991
[11] 吴勇国:板料成形数值模拟研究,华中理工大学博士学位论文,1995
[12] 柳玉起:板材成形塑性流动规律及起皱破裂回弹的数值研究,长春:吉林工业大学,1995
[13] 李广权:板料无模多点成形过程数值模拟研究,长春:吉林工业大学,1997
[14] 张凯峰:三维板壳成形过程的粘塑性有限元分析,中国机械工程学会锻压分会第六届学术年会,北京,1995
[15] 王忠金,王仲仁:板料粘性介质胀形过程应变速率变化的模拟研究[J],塑性工程学报,1999.6(3):46-48
[16] 王晓林,周贤宾:板料成形接触摩擦过程的有限元模拟技术研究[J],塑性工程学报,2000.7(1):18-21
[17] 王晓林,周贤宾:板料成形数值模拟接触搜索模型的研究[J],北京航天航 空大学学报,2000.3.NO.3
[18] 蔡中义,李明哲,陈庆敏:大变形中摩擦接触问题的数值模拟及应用[J],应力力学学报,2002.6.NO.2
[19] 隋阿军,马正元:板料成形过程数值模拟中的接触分析[J],沈阳工业大学学报,2000.2.NO.1
[20] 孙希延,李泉永,杨连发:板料拉深成形数值模拟中动态接触的处理[J],模具工业,2002.NO.8
[21] 苏岚,王先进,唐荻,孙吉先,田荣彬:有限元法处理金属塑性成型过程的接触问题[J],塑性工程学报,2000.12.NO.4
[22] 李尧臣:金属板料冲压成形的有限元法模拟[J],力学学报,1995.27(3) 351-364
[23] 汪晨:板料成形回弹的数值模拟及考虑回弹反向补偿的模具设计方法研究,上海:上海交通大学,1999
[24] 戴雄杰:摩擦学原理,上海科学技术出版社,1984
[25] 温诗铸:摩擦学原理,北京:清华大学出版社,1990
[26] 沈心敏,闻英梅等:摩擦学基础,北京:北京航空航天大学出版社,1991
[27] B. H. Lee, Y. T. Keum, R. H. Wagoner. Modeling of the friction caused by lubrication and surface roughness in sheet metal forming. Journal of Materials Processing Technology 130-131(2002) 60-63.
[28] S. Zhang, P. D. Hodgson, M. J. Cardew-Hall, S. Kalyanasundaram. A finite element simulation of micro-mechanical frictional behaviour. Journal of Materials Processing Technology 134(2003) 81-89.
[29] B. Ma, A. K. Tieu, C. Lu, Z. Jiang. A finite-element simulation of asperity flattening in metal forming. Journal of Materials Processing Technology 130-131(2002) 450-455
[30] E. Doege, C. Kaminsky, A. Bagaviev. A new concept for the description of surface friction phenomena. Journal of Materials Processing Technology 94(1999) 189±192.
[31] J. M. Lanzon a, M. I. Cardew-Hall b, P. D. Hodgson. Characterising frictional behaviour in sheet metal forming. Journal of Materials Processing Technology 80-81(1998) 251-256.
[32] S. Zhang, P. D. Hodgson, J. L. Duncan, M. J. Cardew-Hall, S. Kalyanasundaram. Effect of membrane stress on surface roughness changes in sheet forming. Wear 253(2002) 610-617.
[33] Andrzej Matuszak. Factors infuencing friction in steel sheet forming. Journal of Materials Processing Technology 106(2000) 250±253.
[34] S. S. Han. The influence of tool geometry on friction behavior in sheet metal forming. Journal of Materials Processing Technology 63(1997) 129-133.
[35] 钟志华,李光耀:冲压成形CAE技术中接触摩擦计算的新方法[J],机械工程学报,2001,37(2):33-37
[36] B. H. Lee, Y. T. Keum, R. H. Wagoner. Modeling of the friction caused by lubrication and surface roughness in sheet metal forming. Journal of Materials Processing Technology 130-131(2002) 60-63
[37] Yuan Zhang: Investigation of friction compensation based on velocity estimation method and high-accuracy laser, Graduate Department of Mechanical and Industrial Engineering University of Toronto, 2002
[38] Aleksander Czekanski: Novel nonlinear finite element analysis of dynamic contact problems using variational inequalities, Graduate Department of Mechanical and Industrial Engineering University of Toronto, 2001
[39] Bernand F. Boueri: On-line friction modeling, estimation and compensation for position control. A dissertation presented to the graduate school of the university of florida in partial fulfillment of the requirements for degree of doctor of philosophy. University of florida 2002
[40] Lorenzo M. Smith: Solid finite elements for sheet metal forming simulation, A dissertation submitted to Michigan State University in partial fulfillment of the requirements for the degree of doctor of philosophy, Depart of materials science and mechanics, 1999
[41] Swift H W. Plastic Bending under Tension. Engineering, 1948, 3(2): 333-359
[42] Nine H D. Drawbead Force in Sheet Metal Forming. Proceedings of A Symposium on Mechanics of Sheet Meta] Forming: Behavior and Deformation Analysis, Warren, Michigan, Planum Press, 1978: 179-211
[43] Deng Z, Lovell M R. Effect of Lubrication and Die Radius on The Friction Behavior of Pb-coated Sheet Steels. Wear, 2000, 244(1-2): 42-52
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