Sensitivity Analysis of Effect Related with Material Process and Assembly Variations to Loads Deformation and Stress on HSS Stamping Die

During stamping process, the material properties, process design parameters and production environments inevitably have variation and noisy factors, which possibly affect the sheet metal formability and the deformation of the die structure.After gaining a success in applying sheet metal forming numerical simulation analysis to get the forming loads during stamping process, a methodology of die structure analysis based on sheet metal forming simulation was proposed and validated by experiments.Based on these results, the effect related with initial blank thickness, blank holder force, blank positioning error and die alignment error variations to a DP600 hyperbolic bottomed cup drawing die's forming loads(especially unbalanced loads), and deformation and stress was studied numerically.The influence level of these variations to the die's forming loads, deformation and stress was disclosed.The findings can guide die design, die tryout and process control for high-strength steel(HSS) stamping with increased forming load and decreased sheet metal formability.     

Investigation on Two Electrically-Assisted Forming Processes of AZ31B Magnesium Alloy Sheets

Two new types of electrically-assisted forming(EAF) processes of AZ31B magnesium alloy sheets,i.e., electrically-assisted blanking(EAB) and electrically-assisted sheet upset-extruding(EASUE), are proposed in this paper. During EAB, pulsed current(PC) decreases blanking load and improves blanked surface quality,and higher frequency has a more effective improvement; when the frequency reaches 600 Hz, the whole punched hole fracture is improved to smooth zone. Moreover, EAB does not influence the microstructure and does not induce obvious annealing, and this process is advantageous to the materials that cannot change microstructure.During EASUE, PC can reduce extrusion load and enhance extrusion height, and higher frequency also has a more effective improvement. Both processes indicate that introducing PC can effectively improve the part quality and have an application prospection.     

KEY TECHNOLOGY IN INTELLIGENT CONTROL FOR SHEET METAL DEEP DRAWING

Introduction　　 With development of economics and furtheropening,competitions in market are intensive.The margin between the material cost and price ofproducts becomes small,which compels companiesto pursue higher rate of productivity and quality.The rate of productivity has been improvedthrough high pressing automation,but in order toget satisfactory quality of products under distur-bances,on- line measurement,identification,pre-diction and on- line control must be realized. Intel-ligentcont…     

An Approach to Determine Tool Speed for Cylindrical Part Drawing

In order to evaluate inertial effect on sheet deformation in the simulation of stamping processes by dynamic explicit FEM, an analytic model is established for analyzing cylindrical cup drawing process. The main factors governing the extent of inertial effect on sheet deformation pattern are investigated by energy method, and the approach to the selection of reasonable tool speed for dynamic analysis of stamping processes is proposed. The effectiveness of the present approach is further demonstrated and justified by the numerical result herewith provided.     

基于ABAQUS的深海采矿扬矿管纵向振动性能

为了研究复杂阶梯状扬矿管在采矿船升沉运动和海流作用下的纵向振动特性，利用连续弹性杆振动理论，对5 000 m长扬矿管纵向振动性能进行分析. 首先，根据达朗贝尔原理建立扬矿管纵向振动数学模型，采用分离变量法推导管道固有频率方程；然后，进行振型的质量归一化处理；最后，利用ABAQUS软件建立扬矿管有限元模型，对管道的纵向动态响应进行研究. 研究结果表明:扬矿管的一阶纵向共振频率处于矿区海浪能量集中的频带内，随着中间矿仓质量的增加扬矿管固有频率减小，中间矿仓质量对高阶固有频率的影响更加明显；随着海浪频率的增加，纵向振幅、轴向力和轴向应力先增大后减小，并在一阶固有频率时达到峰值，其峰值分别发生在扬矿管5 000、0、1 000 m处；随着采矿船升沉幅值的增加，扬矿管的动态响应逐渐增大，当升沉幅值大于1.5 m时，扬矿管动态响应的增长速度变缓；扬矿管发生一阶纵向共振时，振动位移和轴向力先增大后作等幅稳态振荡；随着海水深度的增加，沿管长方向的振动幅值逐渐增大，振动平衡位置发生下移，振动响应时间发生延迟，同时轴向力和轴向应力逐渐减小，且轴向应力在每两级阶梯管间急剧变大.      

聚氨酯泡沫塑料振动性能的试验研究

设计了泡沫塑料隔振材料振动特性试验装置,对一种增强型聚氨酯泡沫塑料隔振材料进行了试验.试验 结果表明,泡沫塑料隔振材料的振动特性不仅与振幅有关,还与振动频率有关;恢复力同时受频率和振幅的影 响,并与变形历史有关,具有非线性滞后特性;在振动情况下运动中泡沫塑料表现出动刚度非线性和阻尼非线性 的特性,变化十分复杂.      

支撑刚度对载流摩擦磨损特性的影响

在CETR UMT-2摩擦磨损试验机上,用自行设计的夹具,研究了支撑刚度对钢铝复合轨与受电靴摩擦副之间的载流摩擦磨损特性的影响,测量了法向力随时间的变化曲线与受电靴的磨损质量和弹簧在加、卸载过程中的变形能,分析了变形能与载流摩擦磨损特性之间的关系。分析结果表明:随着载荷的降低,载荷振幅均增大;弹性支撑时的载荷振幅和磨损质量总体上较刚性支撑的小;弹簧的摩擦耗能与变形能的比值越大,吸振能力越强,载荷振幅越小,载流磨损质量越低。可见,弹性支撑能降低载荷的振幅,保证良好的受流,选择合适的加载范围和一定刚度的弹簧支撑能有效地降低电弧烧蚀带来的材料损失,延长摩擦副的使用寿命。     

基于HyperXtrude的薄壁铝型材挤压成形仿真模拟

基于HyperXtrude软件分析薄壁六边形结构挤压成形稳态过程,研究不同状态下金属材料的应力应变、挤压力变化、流速变化和温度等物理参数量的变化趋势,以这些物理参数变化趋势来量化预测该型材挤压成形性。通过仿真模拟清楚反应薄壁六边形结构铝型材在挤压过程的变化特性,预测薄壁结构挤压成形过程中的变形、翘曲、开裂和流速不均等缺陷,为及时对挤压成形工艺方案调整或模具结构改进设计提供指导。     

Numerical Simulation Research on Laser Shock Forming of Thin Metal Sheet

Laser shock forming (LSF) of sheet metal is a new technique realized by applying an impulsive pressure generated by laser-induced shock wave on the surface of metal sheet.LSF of brass sheet metal was investigated using a Q-switched Nd:YAG laser with an energy per pulse of 15～50 joules.ABAQUS software was used to simulate laser shock forming process.The central displacement of the shocked region is measured and compared with the simulation.The higher pulse energy, the higher central displacement of the shocked region were obtained.The deformation of the simulation matches the experiment quite well.     

电气化高速铁路接触网微风振动特性

为评估接触线微风振动现象对接触网运营的的影响,计算不同风速下的接触线风振幅值,基于模态分解法推导了电气化高速铁路接触网垂直方向上的微风振动方程.首先求解出接触网的固有频率与振型,然后推导作用在接触线上的微风激振力,最后计算接触网在发生微风振动时,不同风速作用下各频率对应的振幅.分析风速、频率与振幅的对应关系.结果表明,接触线微风振动的最大幅值一般在1 mm以内,不会产生输电线微风振动时类似的振动幅值;文中算例接触线微风振动最大幅值出现在风速为1.44 m/s时,仅有0.96 mm,不会对电气化铁路的实际运营造成显著影响.      

中低速磁浮车岔耦合振动研究

为研究中低速磁浮道岔主动梁关键参数对车岔耦合振动的影响，进行了各工况下磁浮道岔主动梁的模态测试，并建立了考虑道岔主动梁弹性振动的车岔耦合动力学模型，对悬浮稳定性进行了分析. 通过仿真与试验对比，对道岔主动梁的模态特征进行了修正，并基于修正后的车岔耦合动力学模型，研究了磁浮道岔主动梁不同设计参数对悬浮稳定性的影响规律. 研究结果表明:中间台车采用50 MN/m的弹性约束进行等效，能够达到比较理想的误差要求；二台车支撑方案相比三台车支撑方案，更容易避开磁浮车岔耦合的共振频率；随着主动梁一阶垂向弯曲频率的不断增大，悬浮控制参数的稳定区间越小，当道岔主动梁垂向弯曲频率大于12 Hz时，更容易出现车岔耦合振动现象；随着道岔主动梁刚度的增加，悬浮控制参数的稳定范围越小；增加道岔主动梁结构阻尼比不能解决车岔耦合共振问题，只能降低振动幅值大小；随着道岔主动梁线密度的增大，越不容易出现车岔共振现象，当线密度低于1 500 kg/m时，悬浮稳定区间将急剧下降；中间台车的等效支撑刚度越大，控制参数的稳定区间越小，但影响幅度不大.      

谐波转矩对高速列车齿轮箱体与牵引电机振动特性的影响

为研究机电耦合作用下齿轮箱体和牵引电机的振动幅值、频谱分布及其随高速列车行驶速度的变化趋势, 分析了三相逆变器输出电压谐波频率分布与牵引电机谐波转矩, 建立了传动系统扭振模型; 基于直接转矩控制理论与车辆系统动力学理论, 搭建了牵引电机控制模型和高速列车多体动力学模型; 通过Simulink和SIMPACK联合仿真平台对比了恒力矩输入与含有谐波转矩的力矩输入模型, 分析了不同速度下牵引电机谐波转矩对高速列车齿轮箱体和牵引电机振动特性的影响。分析结果表明: 当高速列车以250 km·h-1的速度匀速运行时, 齿轮箱体大齿轮上方纵向振动、小齿轮上方纵向与垂向振动受牵引电机谐波转矩影响显著, 在700 Hz主频处振动加速度幅值显著增大, 该频率恰为牵引电机输出转矩基波频率的6倍; 在谐波转矩的影响下, 牵引电机在52 Hz主频处横向振动加速度幅值增加52.78%, 在49 Hz主频处垂向振动加速度幅值增加18.95%;随着高速列车速度的增加, 齿轮箱体纵向与牵引电机各向振动加速度逐渐增加, 牵引电机谐波转矩对齿轮箱体纵向振动加速度均方根的影响逐渐减小, 在6倍基波频率处, 齿轮箱体小齿轮上方和牵引电机纵向与垂向振动加速度均先增大后减小, 在速度为250 km·h-1时达到极大值, 且齿轮箱体和牵引电机的垂向振动受6倍基波频率谐波转矩的影响比纵向振动更为明显, 而其横向振动特性几乎不受谐波转矩的影响。      

Experimental exploration of electrical pulse-assisted roller hemming of AZ31B magnesium alloy sheet

The purpose of this research is to explore the feasibility of roller hemming of AZ31B magnesium alloy sheet. During the test, a special experimental setup considering the current flow and insulation was designed and employed. For the sake of simplicity, the flat surface-straight edge hemming style was selected. Electrical pulses were introduced in the pre-hemming and final hemming processes. The results show that when hemming at 448 K with hemming speed of 30 mm/min, AZ31B magnesium alloy sheet was successfully hemmed with excellent perceived quality. No recoil/warp defect, cracking or springback was observed. Electrical pulses induced dynamic recrystallized grains were observed along the grain boundaries in the severely deformed area, which is of great importance to the improvement of the ductility of the material. The hardness was slightly increased after hemming with electrical pulses, and this fact could improve the friction resistance performance of the hemmed part.     

高频振动贯入灌注桩套管土塞效应的数值分析

为探讨大直径灌注桩套管在高频振动贯入时管端土塞效应的形成机理,采用三维颗粒离散元法进行了数值仿真分析,研究了贯入过程中套管内、外土颗粒的位移、速率与接触应力、土塞高度、孔隙率和土体剪应力的变化.仿真结果表明:高频激振力越大,套管贯入深度越大,相应地管内土塞高度也越大,且超孔隙水压波动的最大幅度和幅值越大;土塞上部孔隙率较大,下部土体较密实.在高频振动贯入过程中,套管端沉入处的超孔隙水压幅值最大,同一时刻土塞内的超孔隙水压随深度增大;管内土颗粒在振动开始时以较小幅度上移;套管端部颗粒接触数目随贯入深度和振动频率的增大而增多,且接触应力和土体剪应力比其他区域大.      

磁性液体阻尼减振器的实验研究

针对航天器中一些部件具有频率低、位移小、加速度小的振动特征,设计了专门的实验台,研究了一种结构简单的磁性液体阻尼减振器．在减振过程中,该磁性液体阻尼减振器的能量主要通过摩擦和永磁铁吸附磁性液体的弹性变形来耗散．根据能量耗散机理,通过实验研究分析了磁性液体的种类、体积及永磁铁的形状等因素对磁性液体阻尼减振器减振效果的影响．研究结果表明,在煤油基磁性液体中,柱状磁铁的减振时间随着磁性液体体积的增加而减少;环状磁铁的减振时间随磁性液体体积的增加而减少;在机油基磁性液体中,柱状磁铁的减振时间随着磁性液体体积的增加而增加,环状磁铁的减振时间随着磁性液体体积的增加而减少．     

组合载荷作用下动车牵引电机转子系统弯扭耦合振动特性

为了研究组合载荷作用下动车组用牵引电机转子弯扭振动机理和识别典型故障特征, 依据动车牵引电机结构特点, 将其转子结构离散化为集总质量盘轴系统, 得到了电机转子系统的10自由度弯扭力学模型; 考虑定转子静动气隙偏心引起的不平衡磁拉力、转子质量偏心引起的机械不平衡力、转子重力以及电机驱动转矩和负载转矩等径向和扭转载荷作用, 利用拉格朗日方程法建立了牵引电机转子系统弯扭耦合运动微分方程; 基于Runge-Kutta法求解和分析了不同组合载荷工况作用下的转子系统弯扭振动特性。分析结果表明: 由转子质量偏心造成的系统弯扭自由度耦合关系, 使得牵引电机转子系统的弯扭振动特性受到转子径向和扭转载荷的共同影响, 且影响规律符合转子质量偏心耦合规律; 在全部径向和扭转载荷作用下, 牵引电机转子的径向振动包含零频、转频、二倍转频、弯振固有频率、二倍供电频、二倍供电频与转频组合、脉动转矩频率与转频组合等频率成分, 其中转频成分对应的弯振幅值最大, 而脉动转矩频率与转频的组合频率的振幅非常小, 说明脉动转矩对牵引电机转子径向振动的贡献并不明显; 在全部载荷作用下牵引电机转子的扭转振动包含转频、二倍转频、弯振固有频率与转频组合、二倍供电频与转频组合、脉动转矩频率等频率成分, 其中脉动转矩频率成分对应的扭振幅值最大, 其次由重力和不平衡磁拉力引起的转频成分对应的扭振幅值也较大, 且基本具有同一数量级, 表明它们对扭振的贡献均不能忽略。      

Field Tests for Investigating the Extraction Rate of Piles Using a Vibratory Technique

Factors directly affecting the extraction rate of the piles pulled out by a vibratory pulling system are summarized and classified into five categories (excitation force, resistance, vibration amplitude, pile plumbness keeping, and slowing down at the later stage) from the mechanics and engineering practice. Field tests on steel sheet piles extracted by vibratory technique in different soil conditions are conducted to ascertain how these factors affect the extraction rate of a pile with regard to three major actors of vibratory pile pulling: the pile to be extracted, the selected pulling system, and the imposed soil conditions. The extraction rates of three different sheet pile types (having up to four different lengths) pulled out by two different vibratory pulling systems are documented. The piles with different lengths and types, pulled out with or without a clutch, have different extraction rates. The working parameters governing the vibratory hammer, such as excitation force and vibration amplitude, exert significant influences on the rate of pile extraction, especially in the early stages of up-lift process. The extraction rate of the piles driven in different soil conditions is uniform because different extraction resistances mainly refer to shaft friction. The properties of the pile-soil interface influence the extraction rate of the piles, and the extraction rate decreases with the time for which the piles have been buried in the earth.     

Study on Factors Affecting Springback and Application of Data Mining in Springback Analysis

Springback of sheet metal induced by elastic recovery is one of major defects in sheet metal forming processed. Springback is influenced by many factors including properties of the sheet material and processing conditions. In this paper, a springback simulation was conducted and comparisons between the results based on different processing variables were illustrated. The discovery of knowledge of the effects of geometry and process parameters on springback from FEM results becomes increasingly important, as the number of numerical simulation has grown exponentially. Data mining is an effective tool to realize knowledge discovery in simulation results. A datamining algorithm, rough sets theory (RST), was applied to analyze the effects of process parameters on springback in U-bending.     

The Size Effects on Process Design of Micro Deep Drawing

This paper suggested to reformulate cylindrical deep drawing parameters with dimensionless form. A diagram, in which a feasible zone is drawn to bound both the maximal allowable tension and compression stress during the deep drawing process, was established. Since it is presented in a dimensionless form, it may be applied for both conventional and micro deep drawing. Cylindrical cup deep drawing was taken as an example to show the dimensionless process design method. In addition, the size effects should be taken into account. Two kinds of size effects on micro deep drawing were investigated, which can be explained by surface layer model and strain gradient model. Numerical simulations were carried out to compare the strain distribution with or without consideration of size effect.     

Investigation on blanking of thick sheet metal using the ductile fracture initiation and propagation criterion

In metal forming processes such as sheet blanking, severe plastic deformation localizes in a narrow shear band near blanking clearance, and ductile fracture occurs at the final stage. Because the combinations of large nonlinear strain localization, displacement discontinuity and ductile fracture brought obstacles to numerical simulation, a ductile fracture initiation criterion model and an elasto-plastic finite element method (FEM) were presented to simulate localized severe plastic deformation. Initiation and propagation of cracks were treated by deletion-and-replacement approach. The distributions and developing trends of effective strain and damage were predicted, the influence of blanking clearance on fracture was discussed, and an experiment was performed to explore the forming mechanism.