U型材单轴柔性滚弯成形技术研究及其有限元分析
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摘要
单轴柔性滚弯是一种先进的、高度柔性的钣金制造工艺,与传统的弯曲方法相比,生产的弯曲件具有强度高、表面质量好、成本低等特点,特别适用于航空航天及汽车工业中小批量甚至是单件零件的生产。本文详细地介绍了单轴柔性滚弯技术,主要研究工作如下:
1.根据单轴柔性滚弯成形技术原理,在实验室现有设备数控渐进成形机床的基础上,设计滚弯U型截面型材的滚弯装置。实验研究表明,单轴柔性滚弯系统存在一临界进给量,当进给量超过该值后,工件弯曲曲率半径不再随进给量的增大而变小,达到一个极限半径,并且该半径与刚性滚的直径成正比。
2.从单轴柔性滚弯过程受力分析方面着手,在对工件受力与变形情况进行一些假设简化的基础上,根据弹塑性理论提出了描述单轴柔性滚弯U型截面型材的理论模型,获得了工件回弹后曲率半径与各个主要影响因素之间的理论公式。
3.在有限元分析当中,常用应变能函数描述橡胶材料的力学性能。本文对橡胶类材料的常用应变能函数进行了描述,以“Mooney-Rivilin”模型为本文有限元分析中橡胶的本构模型,利用单轴拉伸和单轴压缩实验数据拟合“Mooney-Rivilin”模型的两参数。
4.利用有限元软件MSC.marc建立了单轴柔性滚弯U型材模型,并对成形及回弹过程进行了有限元模拟仿真。根据有限元计算结果,对影响工件回弹成形的参数进行了分析,验证了实验中得出的柔性滚弯技术的重要特征,与实验结果对比表明,有限元分析具有较高的精度,有一定的实际应用价值。
Single-Axle Bending Technique with Elastic Rubber(SABTER) is an advanced and highly flexible manufacturing technology for sheet metal forming. Compared with the traditional bending method, the products of bending have the advantages of high strength, good surface quality and low cost. It is especially suitable to aerospace and automobile industries with single or mini-batch production.In this study, the principle of the technique is discussed comprehensively. The main work and results in this dissertation can be concluded as follows:
1、According to the principle of the SABTER, a U-profile roll bending device which is based on NC incremental forming machine tools is designed. The experimental research indicates that SABTER has a critical feed .The radius of curvature is no longer changed with the feed increasing when the feed exceed the critical feed. A limit radius that is proportional to the diameter of the rigid roller may be obtained.
2、Based on the force analysis of the SABTER and a series of simplifying for the stress and deformation of the workpiece, a theoretical mould that describes the flexible roll bending the U-profile is proposed by the description of elastic-plastic theory.With this theoretical mould, the formula about the curvature radius of the workpiece and the major influencing factors have been found.
3、In finite element analysis, the mechanical property of rubber material is always described by strain energy function. In this paper, some commonly used strain energy functions of the rubber are described. The“Mooney-Rivilin”material model is used in FEA. Data of Uniaxial tension and compression tests are inputted into Msc.marc software package to compute the two parameters of Mooney-Rivilin material model.
4、The FEA model of the flexible roll bending U-profile has been built with the FEA software Msc.marc. The loading and Springback process have been simulated. With the results of FEA, major factors related to springback have been analyzed and the important feature of SABTER from experiment has been verified. Compared with the experimental results, it shows that the simulation has a good precision and the FEA mode has a certain practical application value.
1.根据单轴柔性滚弯成形技术原理,在实验室现有设备数控渐进成形机床的基础上,设计滚弯U型截面型材的滚弯装置。实验研究表明,单轴柔性滚弯系统存在一临界进给量,当进给量超过该值后,工件弯曲曲率半径不再随进给量的增大而变小,达到一个极限半径,并且该半径与刚性滚的直径成正比。
2.从单轴柔性滚弯过程受力分析方面着手,在对工件受力与变形情况进行一些假设简化的基础上,根据弹塑性理论提出了描述单轴柔性滚弯U型截面型材的理论模型,获得了工件回弹后曲率半径与各个主要影响因素之间的理论公式。
3.在有限元分析当中,常用应变能函数描述橡胶材料的力学性能。本文对橡胶类材料的常用应变能函数进行了描述,以“Mooney-Rivilin”模型为本文有限元分析中橡胶的本构模型,利用单轴拉伸和单轴压缩实验数据拟合“Mooney-Rivilin”模型的两参数。
4.利用有限元软件MSC.marc建立了单轴柔性滚弯U型材模型,并对成形及回弹过程进行了有限元模拟仿真。根据有限元计算结果,对影响工件回弹成形的参数进行了分析,验证了实验中得出的柔性滚弯技术的重要特征,与实验结果对比表明,有限元分析具有较高的精度,有一定的实际应用价值。
Single-Axle Bending Technique with Elastic Rubber(SABTER) is an advanced and highly flexible manufacturing technology for sheet metal forming. Compared with the traditional bending method, the products of bending have the advantages of high strength, good surface quality and low cost. It is especially suitable to aerospace and automobile industries with single or mini-batch production.In this study, the principle of the technique is discussed comprehensively. The main work and results in this dissertation can be concluded as follows:
1、According to the principle of the SABTER, a U-profile roll bending device which is based on NC incremental forming machine tools is designed. The experimental research indicates that SABTER has a critical feed .The radius of curvature is no longer changed with the feed increasing when the feed exceed the critical feed. A limit radius that is proportional to the diameter of the rigid roller may be obtained.
2、Based on the force analysis of the SABTER and a series of simplifying for the stress and deformation of the workpiece, a theoretical mould that describes the flexible roll bending the U-profile is proposed by the description of elastic-plastic theory.With this theoretical mould, the formula about the curvature radius of the workpiece and the major influencing factors have been found.
3、In finite element analysis, the mechanical property of rubber material is always described by strain energy function. In this paper, some commonly used strain energy functions of the rubber are described. The“Mooney-Rivilin”material model is used in FEA. Data of Uniaxial tension and compression tests are inputted into Msc.marc software package to compute the two parameters of Mooney-Rivilin material model.
4、The FEA model of the flexible roll bending U-profile has been built with the FEA software Msc.marc. The loading and Springback process have been simulated. With the results of FEA, major factors related to springback have been analyzed and the important feature of SABTER from experiment has been verified. Compared with the experimental results, it shows that the simulation has a good precision and the FEA mode has a certain practical application value.
引文
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2. A. F.Dix, R. Parkin.Titanium Metal Fabrications in Aero Engines, The Science Technology and Application of Titanium, 1970
3. M. Geiger, H. Arnet, U. Engel.Flexibles Biegen strangepresster Aluminium-profile, Blech Rohre Profile, 1995,42 (1): 31～34.
4. M. Geiger, H. Arnet, F. Vollertsen.Path planning for a kinematic section bending process,Production Engineering, vol. IV: 2, WGP, Berlin, 1997
5. H. Arnet, M. Geiger.Controlled section bending by using a neural network, in Proceedings of the 29th CIRP International Seminar on Manufacturing Systems, Osaka, Japan, 1997,108~113
6. H. Arnet, M. Geiger, F. Vollertsen.Section bending between a rigid roller and an elastic pad, in: U.P. Singh, Sheet Metal, University of Ulster, 1997, 451~461.
7. H. Arnet.Section bending with kinematic shaping, in: Advanced Technology of Plasticity, Proceedings of the Sixth International Conference on Technology Plasticity, Nuremberg, 1999, 2349～2354.
8. H.C.Kwon, Y.T.Im, D.C. Ji.The bending of an aluminum structural frame with a rubber pad, J. Mater. Process Technol, 113 (2001) 786~791
9. J.W.Lee, H.C.Kwon, M.H.Rhee.Determination of forming limit of a structural aluminum tube in rubber pad bending, Journal of Materials Processing Technology140 (2003) 487~493.
10.鲁世红,恽君壁.具有柔性滚轴的两轴卷筒机研制[J]锻压机械,2002,37(1),16～17
11.闫静,左敦稳,王珉.双轴柔性滚弯技术的有限元分析[J]机械科学与技术,2003,22(2)203~205
12.余国庆,鲁世红.基于有限元分析的二轴柔性滚弯过程影响因素的研究,机械科学与技术,2005 24(10) :1187～1190
13.孙卫祥,左敦稳,曹振中.双轴柔性滚弯技术数控系统的研究与开发,[J]机械制造与自动化,2002(5):26~31
14.仲昕.柔性滚弯技术的实验和理论研究,[硕士学位论文],南京,南京航空航天大学,2000
15.闫静,左敦稳,王珉.双轴柔性滚弯过程中工件回弹的理论分析[J]兵工学报,2003,24(3)381~384
16.闫静,左敦稳,王珉.塑性精确理论在双轴柔性滚弯技术中的应用,中国机械工程,2005,16 (12):1124～1127
17.屈晓敏,周云飞.双轴滚弯成形机成形过程与设计[J]洪都科技,2003 (1):9~15
18.何祝斌、汤泽军、张琦等.铝合金型材柔性垫滚弯成形实验研究,航空材料学报2006,26(3):299~300
19.朱东波,孙琨,李涤尘,卢秉恒.板料成形回弹问题研究新进展,塑性工程学报2000,7(1):11～17
20. FRANK Vollertsen. Extrusion, channel, and extrusion bending: a review J, Mater. Process Technology, 1999, 87: 1～27
21. Li S, Reid SR.Relationship between the elastic buckling of square tubes and rectangular plates, Journal of Applied Mechanics, 1990,57: 969
22. Edmundo Corona, Suhas P.Vaze.Buckling of elastic-plastic square tubes under bending, International Journal of Mechanical Sciences, 1996, Volume38, Issue 7: 753~775
23. Frode Paulsen, Torgeir Welo.Cross-sectional deformations of rectangular hollow sections in bending: Part II-analytical models, International Journal of Mechanical Sciences, 2001, 43: 131～152
24. Frode Paulsen, Torgeir Welo.Cross-sectional deformations of rectangular hollow sections in bending:Part I. Experiments, International Journal of Mechanical Sciences 2001, 43: 109~129
25. Forde Paulsen, Torgeir Welo, Odd Perry S vik.A design method for rectangular hollow sections in bending, Journal of Material Process Technology, 2001, 113: 699～704
26.贾俐俐,高锦张.汽车门框空腹铝型材弯曲工艺,金属成形工艺,2000,18 (6):34～35
27. O.S. Hopperstad, T. Berstad, H. Ilstad.Effects of the yield criterion on local deformation numerical simulation of profile forming, Journal of Materials Processing, Technology, 1998, 80–81: 551～555
28. O.S. Hopperstad, S. Remseth, B.Leira.Reliability-based analysis of a stretch-bending process for aluminum extrusions, Computers and Structures, 1999, 71: 63～75
29. Arild H.Clausen, Odd S.Hopperstad, Magnus Langseth.Sensitivity of Model parameter stretch bending of aluminum extrusions, International Journal of Mechanical Sciences, 2001, 43:427～453
30.钱志平,吕玫,高才良.中导轨拉弯成形截面畸变控制及模具设计,锻压技术,2001,03:47～48
31. P. V. Marcal, I. P. King.Elastic-plastic analysis of two-dimension stress system by the finite element method, Int.J.Mech.Sci, 1967, 9:143~155
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