金属板材曲线剪切过程仿真研究
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摘要
板材的成型方式有很多种,剪切是其中比较重要的方式之一,因为在各种加工方式中,剪切这种方式最简单,成本低,应用也最广,它可以作为其他冲压加工的原材料。板金属冷弯成型产品越来越多被应用于实际生产中,而剪切是冷弯成型的一道工序,是为它提供冷弯材料,原材料的好坏会直接影响到终端产品的质量好坏。
本文研究的对象是变宽度圆盘剪切机。圆盘剪切机是轧钢机械的重要生产设备之一,具有生产效率高、质量稳定、适于批量生产等特点,能够剪切各种金属板材。但是现有的圆盘剪切机加工的剪切轨迹都是直线剪切,无法实现有一定弧度的曲线剪切,虽然有其他的加工方法能实现曲线的剪切,如线切割和激光加工等,但是生产成本相对较高,没有受到广泛的应用。因此对变宽度圆盘剪切机的研究具有重要的现实意义。
剪切过程最重要的是看重剪切断面质量,而影响断面质量的因素有很多,包括：板厚、间隙、重叠量、速度、刃口倾斜角度等,所以要得到好的断面质量,必须对这些因素进行研究,本文通过有限元软件(DEFORM)对剪切过程进行仿真研究,得出影响断面质量因素的一般规律。
利用Deform 3D和2D有限元分析软件对变宽度圆盘剪切机剪切过程进行有限元数值模拟。通过对变宽度圆盘剪切机剪切过程的仿真分析,得出各种参数对板材剪切加工质量的影响,例如板厚、间隙、重叠量、速度、刃口倾斜角度等。说明有限元方法对于板材剪切的分析研究具有巨大的潜力。
通过对变宽度圆盘剪切机剪切过程进行初步研究,为将来进一步深入研究奠定了基础,并且对实际剪切过程有一定的实践指导作用。
There are many kinds of sheet forming methods, and shearing is one of the most important methods, because the shearing is simple, low cost and more extensive, it can also serve as the materials for other stamping processing. The production of flexible roll forming is more and more applied in actual manufacture, and shearing is one of the procedures and provide materials for the flexible roll forming. The quality of raw materials will directly affect the quality of the terminal product.
This paper sets the flexible slitting machine as the research object. Disc cutting machine is one of the important equipments with high efficiency, stable quality, suitable for mass production, and it is widely used in all kinds of metal plate shearing. The currently available slitting machine cannot achieve slitting any curve. Although some new-style processing methods, such as wire cutting and laser machine, can achieve shearing of arbitrary curve, it has high production cost. Thereby the research of flexible slitting machine has practical significance.
The shear section quality is the most important in shearing processing. There are many factors that influence the quality of cross section, including:thickness, clearance, overlapping quantity, speed, the blade Angle and so on. So if we want to get good cross-section quality, we must make research of these factors. Through the finite element software (DEFORM) we make the research of shear process simulation,and get the general rule of these factors.
We make the simulation for flexible slitting machine shearing process using Deform 3D and 2D finite element analysis software. Through analysis to flexible slitting machine shearing process simulation, we get the influence that various parameters of plate to the shear processing quality, such as thickness, clearance, overlapping quantity, speed, the blade Angle. It explain that the finite element method for the analysis of sheet shear research has a great potential.
Through the basic research on the flexible slitting machine, provide the foundation for further research, and it has the instruction function to the actual shear process.
本文研究的对象是变宽度圆盘剪切机。圆盘剪切机是轧钢机械的重要生产设备之一,具有生产效率高、质量稳定、适于批量生产等特点,能够剪切各种金属板材。但是现有的圆盘剪切机加工的剪切轨迹都是直线剪切,无法实现有一定弧度的曲线剪切,虽然有其他的加工方法能实现曲线的剪切,如线切割和激光加工等,但是生产成本相对较高,没有受到广泛的应用。因此对变宽度圆盘剪切机的研究具有重要的现实意义。
剪切过程最重要的是看重剪切断面质量,而影响断面质量的因素有很多,包括：板厚、间隙、重叠量、速度、刃口倾斜角度等,所以要得到好的断面质量,必须对这些因素进行研究,本文通过有限元软件(DEFORM)对剪切过程进行仿真研究,得出影响断面质量因素的一般规律。
利用Deform 3D和2D有限元分析软件对变宽度圆盘剪切机剪切过程进行有限元数值模拟。通过对变宽度圆盘剪切机剪切过程的仿真分析,得出各种参数对板材剪切加工质量的影响,例如板厚、间隙、重叠量、速度、刃口倾斜角度等。说明有限元方法对于板材剪切的分析研究具有巨大的潜力。
通过对变宽度圆盘剪切机剪切过程进行初步研究,为将来进一步深入研究奠定了基础,并且对实际剪切过程有一定的实践指导作用。
There are many kinds of sheet forming methods, and shearing is one of the most important methods, because the shearing is simple, low cost and more extensive, it can also serve as the materials for other stamping processing. The production of flexible roll forming is more and more applied in actual manufacture, and shearing is one of the procedures and provide materials for the flexible roll forming. The quality of raw materials will directly affect the quality of the terminal product.
This paper sets the flexible slitting machine as the research object. Disc cutting machine is one of the important equipments with high efficiency, stable quality, suitable for mass production, and it is widely used in all kinds of metal plate shearing. The currently available slitting machine cannot achieve slitting any curve. Although some new-style processing methods, such as wire cutting and laser machine, can achieve shearing of arbitrary curve, it has high production cost. Thereby the research of flexible slitting machine has practical significance.
The shear section quality is the most important in shearing processing. There are many factors that influence the quality of cross section, including:thickness, clearance, overlapping quantity, speed, the blade Angle and so on. So if we want to get good cross-section quality, we must make research of these factors. Through the finite element software (DEFORM) we make the research of shear process simulation,and get the general rule of these factors.
We make the simulation for flexible slitting machine shearing process using Deform 3D and 2D finite element analysis software. Through analysis to flexible slitting machine shearing process simulation, we get the influence that various parameters of plate to the shear processing quality, such as thickness, clearance, overlapping quantity, speed, the blade Angle. It explain that the finite element method for the analysis of sheet shear research has a great potential.
Through the basic research on the flexible slitting machine, provide the foundation for further research, and it has the instruction function to the actual shear process.
引文
[1]中国机械工程学会锻压学会.锻压手册(第三卷)冲压.北京：机械工业出版社,1993：83-211
[2]彭建声.冷冲压技术问答(上).北京：机械工业出版社,2000
[3]彭建声.冷冲压技术问答(下).北京：机械工业出版社,2000
[4]李尧,张利君.金属塑性成形原理.北京：机械工业出版社,2004
[5]胡正寰,夏巨谌.材料塑性成形工程上.北京：化学工业出版社,2006
[6]Vukota Boljanovic. Sheet Metal Forming Processes and Die Design, New York:Industrial Press,2004
[7]F. Faura, A. Garcia, M. Estrems. Finite Element Analysis of Optimum Clearance in The Blanking Process. J. Of Material Processing Technology,1998,80-81:121-125
[8]Ward M J. etc. Simulation of a Multi-stage railway wheel and tyre forming process. J. Materials Proc. Tech.,1998.80～81
[9]Z. H. Chen, C. Y. Tang. A study of Strain Localization in the Fine-blanking Process Using the Large Deformation Finite Element Method. J. of Materials Processing Technology.1999,86:163～167
[10]M. Samuel. FEM Simulation And Experimental Analysis of Parameters of Influenee in The Blankng Process. J. of Mrials Processing Technology.1998,84:97～106
[11]YW. Stegeman, A. M. Goi jaeaerts, D.Brokken, etal An ExPerimental And Numerical Study of A Planar Blanking Process. J. of Materials Processing technology.1999,87:266～276
[12]郝南海,吕炎.有限元重新划分网格时新旧网格数据传递的新方法.金属成形工艺.1997,15(3)：25-27
[13]虞益中.对称式曲柄飞剪机的设计研究：[硕士学位论文].无锡：江南大学,2009
[14]张瑞琼.改善厚板滚切式双边剪剪切质量的研究：[硕士学位论文].河北：燕山大学,2008
[15]秦泗吉.板材剪切与冲裁加工过程有限元模拟及实验研究：[博士学位论文].河北：燕山大学,2001
[16]温彤,陈霞.金属板材剪切变形全过程的模拟.磨具技术,2006,4：3-6
[17]金萍.横切机组板材剪切系统研究.机械研究应用,2000,13(4)：18-21
[18]秦泗吉,彭加耕.板材剪切与冲裁加工实验的位移测量系统.锻压技术,2002,4：26-28
[19]秦泗吉,彭加耕.板厚对冲裁力影响规律的研究.金属成型工艺,2002,4：4-7
[20]刘建磊.提高钢板剪切精度.宽厚板,2002,8(1)：21-24
[21]刘建华.材料成型工艺基础.西安电子科技大学出版杜,2007
[22]曹冬生.平行刃剪切机剪刃间隙对剪切力的影响探讨.冶金设备,2000,(6)：52～53
[23]邹家祥.轧钢机械.第3版.北京：冶金工业出版社,2005：257-298
[24]朱姗姗.变宽度圆盘剪切机虚拟样机研究：[硕士学位论文].北京：北方工业大学2010
[25]康凤.厚板冲裁过程的模拟仿真及其参数优化：[硕士学位论文].重庆：重庆大学2005
[26]汪金飞,刘玉慧.冲裁成形与断裂的数值模拟.锻压装备与制造技术,2007,2：72-74
[27]贾俐俐.冲压工艺与模具设计.北京：人民邮电出版社,2008
[28]张莉,李升军.DEFORM在金属塑性成形中的应用.北京：机械工业出版社,2009
[29]方刚,雷丽平,曾攀.金属塑性成形过程延性断裂的准则及其数值模拟.机械工程学报[J],2002,12：21-25.
[30]Freudenthal F A. The Inelastic Behavior of Solids, New York:Wiley,1950.
[31]Rice J R. Tracey D M. On the ductile enlargement of voids in triaxial stress fields. J.Mech. Phys. Solids.1969,17:201～217.
[32]McClintock F A.A criterion for ductile fracture by the growth of hole. J. Appl. Mech,1968,35:363-371.
[33]Cockcroft MG, Latham D J. Ductility and the workability of metals. J. Inst. Mets,1968,96:33～39.
[34]Brozzo P, Deluca B, Rendina R. A new method for the prediction of formability limitsin metal sheets, sheet metal forming and formability. In;:Proceedings of the SeventhBiennial Conference of the International Deep Drawing Research Group,1972.
[35]孟毅,门正兴.锻件切边变形机理及变形规律研究.热加工工艺,2008,23：13-17
[36]温彤,廖林灿.金属剪切过程的理论研究状况.锻压技术,2000,3：44-47
[37]Kohn P(ed).ANSYS User's Manual for Revision5.7. Swanson Analysis Systems. Inc.,1999:23～56
[38]Marc(nd). MARC General Purpose Finite Element Program. User Information Manual (vol. A). MARC Analysis Research Corporation,1999, (2):34～78
[39]Getting Started with Abaqus:Interactive Edition. Version6.4, ABAQUS Inc. Providence,2003:37～48
[40]Wu, Yu Ling, Brand, Joost H. J., van Gemert, Josephus L. A., Verkerk, Jaap, Wisman, Hans; van Blaaderen, Alfons, Imhof, Arnout. A new parallel plate shear cell for in situ real-space measurements of complex fluids under shear flow.2007, 78103902～103902～11
[41]Limei Xu; Yunlong Geng; Yuantai Hu; Hui Fan; Jiashi Yang;Thickness-shear vibration of an AT-cut quartz plate with elliptical electrodes and implications in optimal blank geometry.2009,875～879
[42]Watanabe, A.; Yano, T.;Direction of Displacement in LiNb03X-Cut Plate Shear Transducer.1978,159～160
[43]D. Brokken, A. M. Goijaerts, W. A. M. Brekelmans, Modeling of The Blanking Process.in:ComPutational Plastieity Fundamentals And APPlieations. Vol.2, Barcelona,1997,1417～1424
[45]A. M. Goi jaerts, YW. Stegeman, L. E. Govaeert, D. Brokken. CanANeW ExPerimental And Numerical Study ImProve Metal Blanklng.J. Of Materials Processing Technol.2000, 103:44～50
[46]Zhou, Y. S., Shick, D. V.; Tiersten, H. F.;An analysis of the normal acceleration sensitivity of contoured quartz resonators with simple rectangular supports. IEEE.1983,6:393～400
[47]Samuel M. FEM simulations and experimental analysis of parameters of influence in the blanking process. J. materials Proc. Tech,1998.84
[2]彭建声.冷冲压技术问答(上).北京：机械工业出版社,2000
[3]彭建声.冷冲压技术问答(下).北京：机械工业出版社,2000
[4]李尧,张利君.金属塑性成形原理.北京：机械工业出版社,2004
[5]胡正寰,夏巨谌.材料塑性成形工程上.北京：化学工业出版社,2006
[6]Vukota Boljanovic. Sheet Metal Forming Processes and Die Design, New York:Industrial Press,2004
[7]F. Faura, A. Garcia, M. Estrems. Finite Element Analysis of Optimum Clearance in The Blanking Process. J. Of Material Processing Technology,1998,80-81:121-125
[8]Ward M J. etc. Simulation of a Multi-stage railway wheel and tyre forming process. J. Materials Proc. Tech.,1998.80～81
[9]Z. H. Chen, C. Y. Tang. A study of Strain Localization in the Fine-blanking Process Using the Large Deformation Finite Element Method. J. of Materials Processing Technology.1999,86:163～167
[10]M. Samuel. FEM Simulation And Experimental Analysis of Parameters of Influenee in The Blankng Process. J. of Mrials Processing Technology.1998,84:97～106
[11]YW. Stegeman, A. M. Goi jaeaerts, D.Brokken, etal An ExPerimental And Numerical Study of A Planar Blanking Process. J. of Materials Processing technology.1999,87:266～276
[12]郝南海,吕炎.有限元重新划分网格时新旧网格数据传递的新方法.金属成形工艺.1997,15(3)：25-27
[13]虞益中.对称式曲柄飞剪机的设计研究：[硕士学位论文].无锡：江南大学,2009
[14]张瑞琼.改善厚板滚切式双边剪剪切质量的研究：[硕士学位论文].河北：燕山大学,2008
[15]秦泗吉.板材剪切与冲裁加工过程有限元模拟及实验研究：[博士学位论文].河北：燕山大学,2001
[16]温彤,陈霞.金属板材剪切变形全过程的模拟.磨具技术,2006,4：3-6
[17]金萍.横切机组板材剪切系统研究.机械研究应用,2000,13(4)：18-21
[18]秦泗吉,彭加耕.板材剪切与冲裁加工实验的位移测量系统.锻压技术,2002,4：26-28
[19]秦泗吉,彭加耕.板厚对冲裁力影响规律的研究.金属成型工艺,2002,4：4-7
[20]刘建磊.提高钢板剪切精度.宽厚板,2002,8(1)：21-24
[21]刘建华.材料成型工艺基础.西安电子科技大学出版杜,2007
[22]曹冬生.平行刃剪切机剪刃间隙对剪切力的影响探讨.冶金设备,2000,(6)：52～53
[23]邹家祥.轧钢机械.第3版.北京：冶金工业出版社,2005：257-298
[24]朱姗姗.变宽度圆盘剪切机虚拟样机研究：[硕士学位论文].北京：北方工业大学2010
[25]康凤.厚板冲裁过程的模拟仿真及其参数优化：[硕士学位论文].重庆：重庆大学2005
[26]汪金飞,刘玉慧.冲裁成形与断裂的数值模拟.锻压装备与制造技术,2007,2：72-74
[27]贾俐俐.冲压工艺与模具设计.北京：人民邮电出版社,2008
[28]张莉,李升军.DEFORM在金属塑性成形中的应用.北京：机械工业出版社,2009
[29]方刚,雷丽平,曾攀.金属塑性成形过程延性断裂的准则及其数值模拟.机械工程学报[J],2002,12：21-25.
[30]Freudenthal F A. The Inelastic Behavior of Solids, New York:Wiley,1950.
[31]Rice J R. Tracey D M. On the ductile enlargement of voids in triaxial stress fields. J.Mech. Phys. Solids.1969,17:201～217.
[32]McClintock F A.A criterion for ductile fracture by the growth of hole. J. Appl. Mech,1968,35:363-371.
[33]Cockcroft MG, Latham D J. Ductility and the workability of metals. J. Inst. Mets,1968,96:33～39.
[34]Brozzo P, Deluca B, Rendina R. A new method for the prediction of formability limitsin metal sheets, sheet metal forming and formability. In;:Proceedings of the SeventhBiennial Conference of the International Deep Drawing Research Group,1972.
[35]孟毅,门正兴.锻件切边变形机理及变形规律研究.热加工工艺,2008,23：13-17
[36]温彤,廖林灿.金属剪切过程的理论研究状况.锻压技术,2000,3：44-47
[37]Kohn P(ed).ANSYS User's Manual for Revision5.7. Swanson Analysis Systems. Inc.,1999:23～56
[38]Marc(nd). MARC General Purpose Finite Element Program. User Information Manual (vol. A). MARC Analysis Research Corporation,1999, (2):34～78
[39]Getting Started with Abaqus:Interactive Edition. Version6.4, ABAQUS Inc. Providence,2003:37～48
[40]Wu, Yu Ling, Brand, Joost H. J., van Gemert, Josephus L. A., Verkerk, Jaap, Wisman, Hans; van Blaaderen, Alfons, Imhof, Arnout. A new parallel plate shear cell for in situ real-space measurements of complex fluids under shear flow.2007, 78103902～103902～11
[41]Limei Xu; Yunlong Geng; Yuantai Hu; Hui Fan; Jiashi Yang;Thickness-shear vibration of an AT-cut quartz plate with elliptical electrodes and implications in optimal blank geometry.2009,875～879
[42]Watanabe, A.; Yano, T.;Direction of Displacement in LiNb03X-Cut Plate Shear Transducer.1978,159～160
[43]D. Brokken, A. M. Goijaerts, W. A. M. Brekelmans, Modeling of The Blanking Process.in:ComPutational Plastieity Fundamentals And APPlieations. Vol.2, Barcelona,1997,1417～1424
[45]A. M. Goi jaerts, YW. Stegeman, L. E. Govaeert, D. Brokken. CanANeW ExPerimental And Numerical Study ImProve Metal Blanklng.J. Of Materials Processing Technol.2000, 103:44～50
[46]Zhou, Y. S., Shick, D. V.; Tiersten, H. F.;An analysis of the normal acceleration sensitivity of contoured quartz resonators with simple rectangular supports. IEEE.1983,6:393～400
[47]Samuel M. FEM simulations and experimental analysis of parameters of influence in the blanking process. J. materials Proc. Tech,1998.84