管形件塑性成形过程有限元模拟研究
|
摘要
管形件已广泛应用于航空航天、管路管道、石油化工、轻工、交通运输及日常生活用品等工业部门中,管形件塑性加工是对管坯通过各种塑性加工手段制成管形零件的加工技术。由于管形件塑性加工是指对管坯的二次加工,因此管形件塑性加工属于管坯深加工技术的范畴。
本文简要介绍了管形件成形的方法及有限元模拟在塑性成形中的应用,针对20钢管坯胀形的问题,建立有限元模型,采用有限元模拟软件DYNAFORM,对典型的管形件三通管成形过程进行了模拟,分析了不同的应力应变及各种工艺参数对胀形成形的影响,主要分析了反压力、内压力、两端轴向进给量、厚向异性系数、摩擦系数、圆角半径等对胀形的高度、壁厚的影响。找出其中的规律性,并对其原因进行分析。
由于管形件胀形时变形量较大,各个参数的影响相对复杂,仅仅通过三通管很难说明这些参数变化的规律性,因此又通过对多通管自行车中接头进行模拟,分析内压力、两端轴向进给量及各个参数的影响规律,通过与三通管中各个参数进行比较,优化模拟参数,然后用优化后的模拟参数重新对三通管和中接头进行有限元模拟。
通过分析比较,得到了较为合理的20钢的模拟参数,并用优化的模拟参数对等径四通管进行模拟,验证各个模拟参数的正确性。
Tubular products are more and more extensive used in aeronautics and astronautics, pipeline,petrochemical, light industry, automobile and life supplies and so on. Tubes plastic processing is to form the tubular products making use of plastic processing method. Tubes plastic processing is the secondary processing, so the tubes plastic processing belongs to the field of further machinery technology.
This paper introduced the forming method of tubular products and finite element simulation using in the plastic forming briefly, and established the finite element model of tubular products of 20 steel. Then simulated the process of teetube's bulging forming using the finite element simulation software DYNAFORM and analyzed the stress, strain and other technological parameter that influenced the height and thickness of bulging forming, including the back pressure, internal pressure, amount of feed in the tops, anisotropy coefficient, friction coefficient, radius of rounded angle and so on. Find the regularity and the reason.
Deformation amount of the tubular products is larger in the bulging forming, the influence of parameters is complicated. So it is difficult to illustrate its regularity. It is necessary to simulate the multi-tube -the bicycle frame connector to compared with the teetube in the internal pressure amount of feed and other parameter. Then optimized the simulation parameter and simulated the teetube and multi-tube again using the optimized parameter.
Compared and analyzed with each other and the simulation parameter of 20 steel can be obtained, and be used to simulated the cross pipe to verify the correction of the simulation parameter.
本文简要介绍了管形件成形的方法及有限元模拟在塑性成形中的应用,针对20钢管坯胀形的问题,建立有限元模型,采用有限元模拟软件DYNAFORM,对典型的管形件三通管成形过程进行了模拟,分析了不同的应力应变及各种工艺参数对胀形成形的影响,主要分析了反压力、内压力、两端轴向进给量、厚向异性系数、摩擦系数、圆角半径等对胀形的高度、壁厚的影响。找出其中的规律性,并对其原因进行分析。
由于管形件胀形时变形量较大,各个参数的影响相对复杂,仅仅通过三通管很难说明这些参数变化的规律性,因此又通过对多通管自行车中接头进行模拟,分析内压力、两端轴向进给量及各个参数的影响规律,通过与三通管中各个参数进行比较,优化模拟参数,然后用优化后的模拟参数重新对三通管和中接头进行有限元模拟。
通过分析比较,得到了较为合理的20钢的模拟参数,并用优化的模拟参数对等径四通管进行模拟,验证各个模拟参数的正确性。
Tubular products are more and more extensive used in aeronautics and astronautics, pipeline,petrochemical, light industry, automobile and life supplies and so on. Tubes plastic processing is to form the tubular products making use of plastic processing method. Tubes plastic processing is the secondary processing, so the tubes plastic processing belongs to the field of further machinery technology.
This paper introduced the forming method of tubular products and finite element simulation using in the plastic forming briefly, and established the finite element model of tubular products of 20 steel. Then simulated the process of teetube's bulging forming using the finite element simulation software DYNAFORM and analyzed the stress, strain and other technological parameter that influenced the height and thickness of bulging forming, including the back pressure, internal pressure, amount of feed in the tops, anisotropy coefficient, friction coefficient, radius of rounded angle and so on. Find the regularity and the reason.
Deformation amount of the tubular products is larger in the bulging forming, the influence of parameters is complicated. So it is difficult to illustrate its regularity. It is necessary to simulate the multi-tube -the bicycle frame connector to compared with the teetube in the internal pressure amount of feed and other parameter. Then optimized the simulation parameter and simulated the teetube and multi-tube again using the optimized parameter.
Compared and analyzed with each other and the simulation parameter of 20 steel can be obtained, and be used to simulated the cross pipe to verify the correction of the simulation parameter.
引文
[1]莫德秀,王好臣.复合压力胀形技术及其在管材成形中的应用[J].1998,11:27-31
[2]王同海.管材塑性加工技术[M].北京:机械工业出版社,1997,12-20
[3]王同海,孙胜.管材胀形工艺分类及变形力学特征[J].锻压技术,1999,4:30-32
[4]莫德秀.多通管接头反向加压成型新工艺及其应用[J].山东理工大学学报,2003,17(6):26-29
[5]王成录,单德彬,吕炎.三通管挤胀成形过程三维刚塑性有限元模拟中关键问题处理[J].塑性工程学报,1999,6(4):62-67
[6]王同海,赵新海,赵国群.金属管件复合成形胀形系数的研究[J].锻压机械,1999,2:42-44
[7]Clough R W.Original Formulation of the Finite Element Method.Finite Elements in Analysis and Design,1991,7:89-110
[8]Nielson G.M.,et al,1994,research issues in data modeling for Scientific visalization,IEEE CG & A,14(2)
[9]杨连发,郭成.液压胀形薄壁管材料流动应力方程的构建[J].西安交通大学学报,2006,40(3):332-336
[10]Coupez,T.,Soyris,N.and Chenot,J,L.,1991,3-D,finite Element Modelling Forging Process with Automatic Remeshing,J.of Mater.Process.Techn,27,119-133
[11]Germain,Y.,Chung,K.and Wagoner,R.H.,1989,A Rigid-viscoplastic Finite Element Program for Sheet Metal Forming Analysis,Int.J.Mech.Sci.,31(1):1-24
[12]李乐,周杰,王梦寒等.三通管内高压成形有限元模拟工艺分析[J].塑性加工技术,2004,6:53-55
[13]Surana K S.Transition Finite Elements for Axi-Symmetric Stress Analysis.Int.J.Num.Meth.Eng.,1980,15:809-832
[14]刘艳芳,施法中,徐向阳.板料冲压成形数值模拟中有限元方程求解算法的研究[J].塑性工程学报,2004,13(4):15-19
[15]薛玉雷,陈明和,王喜.基于数值模拟的应力成形极限图的应用研究[J].航空精密制造技术,2006,42(2):26-29
[16]罗亚军,杨曦.板料成形中的有限元模拟技术[J].金属成形工艺,2000,18(6):1-3
[17]Makinouchi A.,1996,Sheet Matal Forming Simulation in Industry,J.of Materials Processing Technology,60,19-26
[18]王勖成.有限单元法[M].北京:清华大学出版社,2003,378-403
[19]叶又,彭颖红,阮雪榆.板料塑性成形分析的若干问题[J].应用基础与工程科学 学报,1997,5(1):6-11
[20]赵婷婷,陈宗民.冲裁模的CAD自动实体建模方法[J].锻压设备与制造技术,2006,2:102-104
[21]M.Ahmed,Finit elemet modeling and sinulation of metal flow inbulge forming,Ph.D.Thesis,Dublin City University,Dublin,Ireland,1997
[22]Kobayashi,S.,Oh,S.I.and Altan,T.,1989,Metal Forming and the Finite Element Method,Oxford University Press,New York
[23]陈文亮.板料成形CAE分析教程[M].北京:机械工业出版社,2005,106-132
[24]霍同如,徐秉业.板料成形的计算机辅助工程系统力学进展[J].1996,32(8):687-708
[25]柳玉启,郭成,胡平等.板料成形离散Kirchhoff理论单元模型[J].塑性工程学报,1995,2(4):31-38
[26]彭颖红,阮雪榆.塑性成形问题中一类表面缺陷的预测研究方法[J].上海交通大学学报,1994,28(4):83-89
[27]Zienliewcz O C,Jain P C.Onat E,Flow of solids during forming andextrusion some aspects of numerical solutions.Int.J.Solids.Struct,1978,14:15
[28]Yingyot A U L,Gracious N,Taylan A.Optimizingtube hydroforming using process simulation and experimental verification[J].Journal of Materials Processing Technology,2004,146(1):137-143
[29]王殿楹.大型薄壁三通管件液压胀形技术探讨[J].重型机械,1997,6:37-40
[30]M.1.Hutchinson,R.Crampton,M.S.Ali,M.S.J.Hashmi,The hudraulic bulg forming if tubular components-the effect of changing the tubeblank material,in:Proceedings of the 4th National Conference in Production Research,Sheffield,1988:439-444
[31]余心宏,翟江波,翟妮芝.三通管复合胀形加载路径研究[J].机床与液压,2007,35(12):71-73
[32]赵长财,周磊,张庆.薄壁管液压胀形加载路径研究[J].中国机械工程,2003,7:1087-1090
[33]袁安营,王忠堂,张士宏.管材液压胀形有限元模拟[J].计算机辅助工程,2006,15:370-373
[34]Li-Ping lei,Dae-Hwan Kim,Sung-Jong Kang,Sang-Moon Hwang,Beom Soo Kang.Analysis and design of hydroforming processes by the rigid-plastic finite element method.Journal of Materials Processing Technology.2001,114:201-206
[35]Wang Tonghai,Sun Sheng,Mo Dexiu.The Research of Tube Bulging Using Polyurethane Under Compound Dxternal Forces and Its Application.Advanced Technology of Plasticity,1993:494-499
[36]李国刚,吕如民.紫铜管三通接头的轴向压缩胀形工艺及模具设计[J].锻压机械,2000,34(4):26-28
[37]常东华,周晓,魏佰友.塑性应变比r值的测定和应用[J].理化实验-物理分册,2006,48(8):401-407
[38]韩英淳,于多年,马若丁.汽车轻量化中的管材液压成形技术[J].汽车工艺与材料,2003,8:23-27
[39]唐信.汽车空调管中三通接头的成形工艺[J].汽车工艺与材料,2000,2:43-44
[40]于强,杨连发,巢鹏飞等.薄壁管液压胀形过程的数值模拟[J].模具工业,2005,297(11):3-6
[41]李靖谊,王化明,张中元.基于非线性有限元的饭金件成形极限研究[J].机械科学与技术,2002,5:517-523
[42]倪向贵,王宇,吴恒安等.用于板料成形数值模拟的各向异性本构模型研究[J].中国科学技术大学学报,2000,30(6):700-706
[43]F barlat,et al.A six-component yield functions for anisotropic materials.International Journal of Plasticity,1991,7:693-712
[44]苑世剑,郎利辉,王仲仁.高内压成形技术研究与应用进展[J].哈尔滨工业大学学报,2000,32(5):60-63
[45]彭颖红.金属塑性成形仿真技术[M].上海:上海交通大学出版社,1999,4,19-35
[46].关小军,高鹏,工作成等.冷轧深冲薄板的模拟成形性能研究[J].锻压技术,2004,2:25-29
[47]张铁山,张友良,王建中等.较厚板料成形的数值仿真[J].现代设计与技术,2003,10:101-103
[48]Greaves D M.Hierarchical tree-based finite element mesh generation.International Journal for Numeric Methods in Engineering,1999,45:447-471
[49]E.Bollinger,D.-W.Jutten,Usinor tubes,Montanaire,Frankreich.Tube for Hydroforming,1999,1(10):97-102
[50]程东明,苑世剑,安学良.内压对Y型三通管内高压成形影响研究[J].塑性工程学报,2006,13(2):10-13
[51]夏巨谌,杨雨春,胡国安等.多通管挤压胀形过程的分析与计算[J].塑性工程学报,2001,18(3):24-28
[52]余心宏,王会风,郑艳丽.三通管复合胀形过程模拟[J].航空精密制造技术2005,41(5):48-50
[53]王卫卫,罗上银.多通管液压胀形技术研究与应用[J].锻压技术,1998,2:37-39
[54]杨海波,杨成,樊百林.异径四通管液压胀形工艺分析及过程仿真[J].北京科技大学学报,2002,24(1):72-75
[55]李鹏耀,周林,崔礼春等.薛克敏加载路径对等径四通管内高压成形的影响[J].合肥工业大学学报,2007,30(9):1121-1124
[56]王丽娟,肖凯伯.多通管的塑挤成形缺陷及防止措施[J].锻压机械,1999,3:22-23
[2]王同海.管材塑性加工技术[M].北京:机械工业出版社,1997,12-20
[3]王同海,孙胜.管材胀形工艺分类及变形力学特征[J].锻压技术,1999,4:30-32
[4]莫德秀.多通管接头反向加压成型新工艺及其应用[J].山东理工大学学报,2003,17(6):26-29
[5]王成录,单德彬,吕炎.三通管挤胀成形过程三维刚塑性有限元模拟中关键问题处理[J].塑性工程学报,1999,6(4):62-67
[6]王同海,赵新海,赵国群.金属管件复合成形胀形系数的研究[J].锻压机械,1999,2:42-44
[7]Clough R W.Original Formulation of the Finite Element Method.Finite Elements in Analysis and Design,1991,7:89-110
[8]Nielson G.M.,et al,1994,research issues in data modeling for Scientific visalization,IEEE CG & A,14(2)
[9]杨连发,郭成.液压胀形薄壁管材料流动应力方程的构建[J].西安交通大学学报,2006,40(3):332-336
[10]Coupez,T.,Soyris,N.and Chenot,J,L.,1991,3-D,finite Element Modelling Forging Process with Automatic Remeshing,J.of Mater.Process.Techn,27,119-133
[11]Germain,Y.,Chung,K.and Wagoner,R.H.,1989,A Rigid-viscoplastic Finite Element Program for Sheet Metal Forming Analysis,Int.J.Mech.Sci.,31(1):1-24
[12]李乐,周杰,王梦寒等.三通管内高压成形有限元模拟工艺分析[J].塑性加工技术,2004,6:53-55
[13]Surana K S.Transition Finite Elements for Axi-Symmetric Stress Analysis.Int.J.Num.Meth.Eng.,1980,15:809-832
[14]刘艳芳,施法中,徐向阳.板料冲压成形数值模拟中有限元方程求解算法的研究[J].塑性工程学报,2004,13(4):15-19
[15]薛玉雷,陈明和,王喜.基于数值模拟的应力成形极限图的应用研究[J].航空精密制造技术,2006,42(2):26-29
[16]罗亚军,杨曦.板料成形中的有限元模拟技术[J].金属成形工艺,2000,18(6):1-3
[17]Makinouchi A.,1996,Sheet Matal Forming Simulation in Industry,J.of Materials Processing Technology,60,19-26
[18]王勖成.有限单元法[M].北京:清华大学出版社,2003,378-403
[19]叶又,彭颖红,阮雪榆.板料塑性成形分析的若干问题[J].应用基础与工程科学 学报,1997,5(1):6-11
[20]赵婷婷,陈宗民.冲裁模的CAD自动实体建模方法[J].锻压设备与制造技术,2006,2:102-104
[21]M.Ahmed,Finit elemet modeling and sinulation of metal flow inbulge forming,Ph.D.Thesis,Dublin City University,Dublin,Ireland,1997
[22]Kobayashi,S.,Oh,S.I.and Altan,T.,1989,Metal Forming and the Finite Element Method,Oxford University Press,New York
[23]陈文亮.板料成形CAE分析教程[M].北京:机械工业出版社,2005,106-132
[24]霍同如,徐秉业.板料成形的计算机辅助工程系统力学进展[J].1996,32(8):687-708
[25]柳玉启,郭成,胡平等.板料成形离散Kirchhoff理论单元模型[J].塑性工程学报,1995,2(4):31-38
[26]彭颖红,阮雪榆.塑性成形问题中一类表面缺陷的预测研究方法[J].上海交通大学学报,1994,28(4):83-89
[27]Zienliewcz O C,Jain P C.Onat E,Flow of solids during forming andextrusion some aspects of numerical solutions.Int.J.Solids.Struct,1978,14:15
[28]Yingyot A U L,Gracious N,Taylan A.Optimizingtube hydroforming using process simulation and experimental verification[J].Journal of Materials Processing Technology,2004,146(1):137-143
[29]王殿楹.大型薄壁三通管件液压胀形技术探讨[J].重型机械,1997,6:37-40
[30]M.1.Hutchinson,R.Crampton,M.S.Ali,M.S.J.Hashmi,The hudraulic bulg forming if tubular components-the effect of changing the tubeblank material,in:Proceedings of the 4th National Conference in Production Research,Sheffield,1988:439-444
[31]余心宏,翟江波,翟妮芝.三通管复合胀形加载路径研究[J].机床与液压,2007,35(12):71-73
[32]赵长财,周磊,张庆.薄壁管液压胀形加载路径研究[J].中国机械工程,2003,7:1087-1090
[33]袁安营,王忠堂,张士宏.管材液压胀形有限元模拟[J].计算机辅助工程,2006,15:370-373
[34]Li-Ping lei,Dae-Hwan Kim,Sung-Jong Kang,Sang-Moon Hwang,Beom Soo Kang.Analysis and design of hydroforming processes by the rigid-plastic finite element method.Journal of Materials Processing Technology.2001,114:201-206
[35]Wang Tonghai,Sun Sheng,Mo Dexiu.The Research of Tube Bulging Using Polyurethane Under Compound Dxternal Forces and Its Application.Advanced Technology of Plasticity,1993:494-499
[36]李国刚,吕如民.紫铜管三通接头的轴向压缩胀形工艺及模具设计[J].锻压机械,2000,34(4):26-28
[37]常东华,周晓,魏佰友.塑性应变比r值的测定和应用[J].理化实验-物理分册,2006,48(8):401-407
[38]韩英淳,于多年,马若丁.汽车轻量化中的管材液压成形技术[J].汽车工艺与材料,2003,8:23-27
[39]唐信.汽车空调管中三通接头的成形工艺[J].汽车工艺与材料,2000,2:43-44
[40]于强,杨连发,巢鹏飞等.薄壁管液压胀形过程的数值模拟[J].模具工业,2005,297(11):3-6
[41]李靖谊,王化明,张中元.基于非线性有限元的饭金件成形极限研究[J].机械科学与技术,2002,5:517-523
[42]倪向贵,王宇,吴恒安等.用于板料成形数值模拟的各向异性本构模型研究[J].中国科学技术大学学报,2000,30(6):700-706
[43]F barlat,et al.A six-component yield functions for anisotropic materials.International Journal of Plasticity,1991,7:693-712
[44]苑世剑,郎利辉,王仲仁.高内压成形技术研究与应用进展[J].哈尔滨工业大学学报,2000,32(5):60-63
[45]彭颖红.金属塑性成形仿真技术[M].上海:上海交通大学出版社,1999,4,19-35
[46].关小军,高鹏,工作成等.冷轧深冲薄板的模拟成形性能研究[J].锻压技术,2004,2:25-29
[47]张铁山,张友良,王建中等.较厚板料成形的数值仿真[J].现代设计与技术,2003,10:101-103
[48]Greaves D M.Hierarchical tree-based finite element mesh generation.International Journal for Numeric Methods in Engineering,1999,45:447-471
[49]E.Bollinger,D.-W.Jutten,Usinor tubes,Montanaire,Frankreich.Tube for Hydroforming,1999,1(10):97-102
[50]程东明,苑世剑,安学良.内压对Y型三通管内高压成形影响研究[J].塑性工程学报,2006,13(2):10-13
[51]夏巨谌,杨雨春,胡国安等.多通管挤压胀形过程的分析与计算[J].塑性工程学报,2001,18(3):24-28
[52]余心宏,王会风,郑艳丽.三通管复合胀形过程模拟[J].航空精密制造技术2005,41(5):48-50
[53]王卫卫,罗上银.多通管液压胀形技术研究与应用[J].锻压技术,1998,2:37-39
[54]杨海波,杨成,樊百林.异径四通管液压胀形工艺分析及过程仿真[J].北京科技大学学报,2002,24(1):72-75
[55]李鹏耀,周林,崔礼春等.薛克敏加载路径对等径四通管内高压成形的影响[J].合肥工业大学学报,2007,30(9):1121-1124
[56]王丽娟,肖凯伯.多通管的塑挤成形缺陷及防止措施[J].锻压机械,1999,3:22-23