船体外板冷弯成形回弹数值模拟关键技术研究

如何精确的预测出回弹量在船体外板冷弯成形中是一个非常关键的因素,有限元数值模拟技术的引入,为推动回弹问题的解决提供了有利的工具.文章基于船体外板多点成形技术冷压成形的回弹数值模拟的数学模型的建立问题,重点介绍了本构模型、单元类型、数值计算方法的选择及接触与摩擦的处理等,为后续的回弹模拟研究奠定了基础.     

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.     

金属成形数值模拟算法及软件开发

以实现拥有部分算法特色的金属成形定制化CAE （computer-aided engineering）软件为目的,在自主开发的OmtDesk平台基础上,嵌入金属成形数值计算程序.首先,以双势理论为基础,运用Uzawa算法求解金属成形中的接触摩擦问题;其次,采用建立在更新拉格朗日框架上的返回映射算法,求解金属成形中材料非线性问题;最后,通过压缩回弹和挤压成形两个数值算例,验证了自主开发的金属成形定制化CAE软件FEM/Form的准确性与通用性,并将求解结果与ANSYS对比.在压缩回弹算例中,采用ANSYS得到10–3 mm量级的穿透量,相同算例采用FEM/Form则能将穿透量控制在10–7 mm量级,说明采用双势接触模块能更加精确地控制金属成形数值模拟中的穿透量,使金属成形过程更加准确.      

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.     

Investigation of springback behavior and process control for stamping of ring-shaped workpiece

Due to the elastic deformation of metal stamping, springback is a serious problem to cause shape deviation and thus reduce precision. The springback behavior of ring-shaped workpiece is investigated in this paper and an auxiliary boss device is proposed to control the springback deformation. A finite element model is developed.The characteristic parameters including boss height, boss angle and boss gap are discussed systematically. It can be concluded that the gap has a positive linear correlation with springback percentage, and the boss angle has an optimal interval of 30°—60° to reduce springback. When the boss height increases, the springback decreases,but the effect weakens when the boss height is larger than 1.0 mm. Then, a response surface analysis is conducted with Design Expert 8.0.5 software and an optimal parameter process window(i.e., boss height from 2.1 to 3.0 mm,boss angle from 53° to 60° and the gap from 0 to 1.2 mm) is obtained. Finally, a set of molds are fabricated and the stamping experiments are conducted. The springback behavior is well controlled. The springback percentage can be decreased from 33% to 6% by using the auxiliary boss device of ring-shaped workpiece.     

A reconfigurable stamping die and its stamping process

A reconfigurable flexible poles die was developed. The die can be used to implement the process of “the multi-point pressing and forming sheet”. Sheet metal is restricted by the elastic pressing forces putting on the upper and lower surfaces of sheet in stamping process. The method is an effective way to enhance the buckling critical stresses and reduce wrinkling of sheet. The results of tests indicate that the die can achieve “one die brings multi-purpose” and suppress the wrinkle of sheet. The process of the multi-point pressing and forming sheet provides a practical and effective way for the curved sheet metal forming.     

货车冲压件CAPP系统的研究

针对货车板材冲压件,就开发其CAPP系统进行了研究。以成组技术的基本原理为依据,提出了零件描述和工艺过程生成的新方法,其主要特点是:计算机辅助编码,运用专家知识库进行决策判断,检索与创成相结合。系统采用模块化的设计方法,做到了系统的柔性化。系统采用了汉字DBASE数据库和MS-PASCAL语言,适用于IBM-PC机及其兼容机。     

冷弯成型局部大变形测试装置的设计与研究

冷弯成型变形复杂，事先难以预测其变形效果。根据冷弯成型的特点和变形规律设计出基于万能实验机上的局部大变形测试装置，并应用此装置对冷弯成型过程进行回弹分析，为冷弯成型理论分析和使用ANSYS／LS-DYNA对冷弯成型分析提供科学依据。     

Bi-phasic Simulation of Metal Injection Moulding： Constitutive Determinations

IntroductionMetalinjectionmolding (MIM )isexpectedtobeveryefficienttoproducesmalland 3Dcomplicatedpartsinlargeseries .Thistechnologycombinesthewell knownpolymerinjectionmouldingandpowdermetallurgytechnology .AnMIM processincludesfourmainstages[1,2 ] :them…     

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.     

CAE-Based Robust Optimization for Deep-Drawing Process of Sheet Metal Forming Using Grey Relational Analysis Method

The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. The grey relational analysis was used to optimize the deep-drawing process parameters with considerations of the multiple response (the wrinkle, crack and thinning variation). The deep-drawing parameters, such as the blank holding force (F_ bh ), the radii of punch and die (R_1,R_2), the coefficients of friction (μ_1,μ_2,μ_3) are considered. An orthogonal array is used for the experimental design. The multiple response values are obtained making use of finite element analysis (FEA). Optimal process parameters are determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (the wrinkle, crack and the thinning). The analysis of variance (ANOVA) for the grey relational grade is implemented. The results show that the quality of stamped parts can be improved effectively through the new approach. The grey relational analysis can be applied in sheet metal forming.     

Simulation of tube forming process in mannesmann mill

The finite element method (FEM) is used for simulation of the tube piercing process in Mannesmann mill. The numerical model is described with taking into consideration thermal phenomena in metal during forming. The simulated results visualize dynamic distributions of mean stresses, temperature, velocity and shear stresses, especially inside the workpiece. On the basis of the basic parameters, the phenomenon in the piercing process is analyzed. The model is verified by comparing the values of calculated force parameters of the piercing process and those measured in laboratory conditions.     

钢-铝石墨半固态铸轧复合的数值模拟

铸轧区的温度分布直接影响着铸轧过程的稳定性和复合板材的质量.针对实验室复合板半固态铸轧试验的特点建立了数学模型,采用有限元法对钢-铝石墨半固态铸轧复合过程的热流耦合问题进行了数值模拟计算,分析了不同浇注温度和铸轧速度下熔池内温度场变化的情况.模拟结果表明,当浇注温度为620℃,铸轧速度在0.6～0.8 m/min的范围内可保证铸轧稳定进行,此结论与试验数据相吻合.该模型可以有效预测凝固前沿位置,为半固态铸轧复合工艺的进一步研究和钢-铝石墨复合板的数字化生产提供了依据.     

金属再结晶组织模拟及实验对比研究

金属再结晶过程计算机组织模拟,可以仿真实验中观测不到的组织演变细节,得到定量的特征参数,预报退火后的材料性能,指导热处理工艺设计。构建一个新的静态再结晶MC Potts模拟模型,并以1060铝合金为研究对象,进行再结晶模拟与实验对比研究。结果表明,1060铝合金表现出明显的再结晶特征,得到了近似等轴晶组织;新模型模拟的再结晶形核位置、组织形貌与实验结果一致,组织演变过程也与实验结果基本一致,但模拟的再结晶等轴晶与实验近似等轴晶不完全一致,模拟的再结晶速度也低于实验结果。     

Thermal flow simulation of twin-roll casting magnesium alloy

In order to better understand twin-roll casting process, a 3D finite element method (FEM) simulation was carried out, based on the conditions of the pilot vertical twin-roll caster, to study the thermal flow and solidification behavior in the twin-roll casting process. The simulation results show that non-uniform temperature and velocity distribution near the side dam region are the main reason for causing non-uniform solidification and non-uniform deformation along the cast sheet width. Therefore, it is necessary to preheat the side dams or improve the design of nozzle to compensate the effect of side dams on the casting process. High quality magnesium sheets have been cast after improved the casting devices.     

金属再结晶组织模拟及实验对比研究

金属再结晶过程计算机组织模拟,可以仿真实验中观测不到的组织演变细节,得到定量的特征参数,预报退火后的材料性能,指导热处理工艺设计。构建一个新的静态再结晶MC Potts模拟模型,并以1060铝合金为研究对象,进行再结晶模拟与实验对比研究。结果表明,1060铝合金表现出明显的再结晶特征,得到了近似等轴晶组织;新模型模拟的再结晶形核位置、组织形貌与实验结果一致,组织演变过程也与实验结果基本一致,但模拟的再结晶等轴晶与实验近似等轴晶不完全一致,模拟的再结晶速度也低于实验结果。     

A bayesian based process monitoring and fixture fault diagnosis approach in the auto body assembly process

The auto body process monitoring and the root cause diagnosis based on data-driven approaches are vital ways to improve the dimension quality of sheet metal assemblies. However, during the launch time of the process mass production with an off-line measurement strategy, the traditional statistical methods are difficult to perform process control effectively. Based on the powerful abilities in information fusion, a systematic Bayesian based quality control approach is presented to solve the quality problems in condition of incomplete dataset. For the process monitoring, a Bayesian estimation method is used to give out-of-control signals in the process. With the abnormal evidence, the Bayesian network (BN) approach is employed to identify the fixture root causes. A novel BN structure and the conditional probability training methods based on process knowledge representation are proposed to obtain the diagnostic model. Furthermore, based on the diagnostic performance analysis, a case study is used to evaluate the effectiveness of the proposed approach. Results show that the Bayesian based method has a better diagnostic performance for multi-fault cases.     

基于Marc金属正交切削过程仿真的参数化建模

对金属正交切削过程的仿真,方便和快捷地对刀具—工件系统进行造型是必要的。本文通过建立刀具、工件的参数化模型并选用了合适的造型方式,应用数据库技术,采用C++Builder软件完成了接口设计;给定刀具的结构尺寸、几何角度和工件的几何尺寸以及刀具与工件的相对位置,即可生成二维造型的的过程文件,并在Marc软件环境中完成刀具—工件的建模。最后介绍了刀具—工件的参数化造型的关键技术及其过程。从而为正交切削过程的数值模拟奠定了基础。     

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.     

铝合金货车侧墙多道焊变形预测

基于热弹塑性有限元法,对铝合金货车侧墙多道焊焊接变形进行仿真预测,仿真中充分考虑了材料热物理属性的影响．基于实体一壳单元混合模型,建立了侧墙有限元网格模型,应用3D高斯双椭球热源模型实现了焊接过程温度场分析．从工程实际出发设计了四种焊接顺序,通过对四种焊序下仿真结果的对比分析,讨论了不同焊接顺序对铝合金货车侧墙焊接成形的影响,为研究大型铝合金薄板焊接过程中的应力应变和减少焊接应力与变形提供了参考依据．