Numerical study of the forming process of high frequency welded pipe

The roll forming process is applied to the manufacturing of high frequency welded (HFW) pipes,section steels,etc. In this paper,the roll forming process of the HFW pipe is simulated with the finite element method (FEM). A user-defined material routine of the commercial finite element code ABAQUS/Explicit is developed,and the mixed hardening constitution model is realized through the user-defined material routine. Based on the mixed hardening constitutive equation,the numerical simulation of roll forming pro...     

冷弯成型过程的有限元模拟

概述了冷弯成型过程有限元数值模拟的基本原理和基本算法，利用ANSYS／LS—DYNA分析软件对冷弯过程进行有限元数值模拟，并对模拟结果进行受力和应变分析以验证其可行性和正确性，为冷弯成型的工程设计提供了科学依据，从而降低设计风险。     

Optimization of Clinching Tools by Integrated Finite Element Model and Genetic Algorithm Approach

Clinching is a convenient and efficient cold forming process that can join two sheets without any additional part. This study establishes an intelligent system for optimizing the clinched joint. Firstly, a mathematical model which introduces the ductile damage constraint to prevent cracking during clinching process is proposed.Meanwhile, an optimization methodology and its corresponding computer program are developed by integrated finite element model(FEM) and genetic algorithm(GA) approach. Secondly, Al6061-T4 alloy sheets with a thickness of 1.4 mm are used to verify this optimization system. The optimization program automatically acquires the largest axial strength which is approximately equal to 872 N. Finally, sensitivity analysis is implemented, in which the influence of geometrical parameters of clinching tools on final joint strength is analyzed. The sensitivity analysis indicates the main parameters to influence joint strength, which is essential from an industrial point of view.     

Engineering design optimization based on intelligent response surface methodology

An intelligent response surface methodology （IRSM） was proposed to achieve the most competitive metal forming products, in which artificial intelligence technologies are introduced into the optimization process. It is used as simple and inexpensive replacement for computationally expensive simulation model. In IRSM, the optimal design space can be reduced greatly without any prior information about function distribution. Also, by identifying the approximation error region, new design points can be supplemented correspondingly to improve the response surface model effectively. The procedure is iterated until the accuracy reaches the desired threshold value. Thus, the global optimization can be performed based on this substitute model. Finally, we present an optimization design example about roll forming of a ＂U＂ channel product.     

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。     

A new approach of intelligent design and optimization for shell nosing

Preform design for shell nosing product without machining the inner surface after forming is an experience-extensive work. Generally, the initial design needs to be modified and simulated consequently to get proper preform and nosing die, and the iterative process is time consuming. This paper puts forward a new approach, in which the suitable initial design can be obtained by knowledge-based intelligent technology and the optimal design can be acquired by finite element method (FEM) based geometrical modification. With the CAX object model as the bridge of CAD and CAE, the CAD model with simulation knowledge can be transferred into CAE automatically, and the CAE result can be automatically utilized as well. Based on the comparison between the simulated shape and the desired shape, the dissatisfactory area will be modified. A new simulation and modification process will be carried out based on the modified design. The process is repeated iteratively to get the optimal design. This approach utilizes the commercial CAD and CAE software, without the need of complex back-forward FEM procedures. Based on the new approach, an in-home intelligent shell nosing design and optimization system is developed, and a case study proves that this system can reach a reasonable design efficiently.     

The Numerical Simulation on Hollow Part''''s Precise Sizing Process With Cross-wedge Rolling

ThepaperwassponsoredbyPanDengBprojectIntroductionThecrosswedgerollingprocesshasmnyadVatages.ItisaldndofneweffectiveandeconomictechnologythatProducesstePPedshaft.ThetOchnologyhowtoimPovetheaccuracyofworkPiecehasbeingdeVeoped.ThediametertoleraneofsolidpartscanbelimitedbetWeen0.2mmto0.5mm.Thelengthtolerancerangedbforeen0.2nuntolmm.TheaccuracyofpatscouldsatsfythePfOcisionlevelofthetoleranceandmachiningallowancesofsteeldieforeingChinesenationalstandard.[l]Butthediametertoleranceofhollowpeds…     

有限元可靠度方法在桥梁工程中的应用

一次二阶矩法是目前求解结构可靠性分析的主要计算方法之一．该方法要求功能函数对随机变量的偏导运算。然而对于以有限元方法分析为主的桥梁结构．无法对其隐式功能函数进行显式求导．限制了一次二阶矩法的应用。本文给出了隐式功能函数可靠度的随机有限元解决方案．考虑了有限元方法和可靠度方法结合使用过程中，经典一次二阶矩法的改造问题。算例表明，该方法能够适用于基于有限元的结构可靠度分析，并在求解过程中给出随机变量的敏感系数。     

FEM Analysis of Tube Preforming and Hydroforming Process for an Automotive Part

The tube hydroforming technology is used today in the mass production of lightweight components for the automotive industries due to its advantages over conventional stamping methods. A typical tube hydroforming process is usually a multiple forming operation process. The tube preforming and hydroforming process of an automobile subframe were analyzed by finite element method (FEM), and a parametric study was also carried out to obtain the effect of the forming parameters such as the die closing, the internal pressure and the axial feeding. The simulation results were also compared with industrial products in respect to the thickness distribution of some typical and key cross-sections. The study indicates that the internal pressure and the axial feeding should be set correctly and the multiple forming operations of tube hydroforming process can be simulated well by using the explicit code Ls-Dyna.     

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.      

Forming path optimization for press bending of aluminum alloy aircraft integral panel

Because of the light weight, high stiffness and high structural efficiency, aluminium alloy integral panels are widely used on modern aircrafts. Press bend forming has many advantages, and it becomes a significant technique in aircraft manufacturing field. In order to design the press bend forming path for aircraft integral panels, we propose a novel optimization method which integrates the finite element method (FEM) equivalent model based on our previous study, the artificial neural network response surface, and the genetic algorithm. First, a multi-step press bend forming FEM equivalent model is established, with which the FEM experiments designed with Taguchi method are performed. Then, the back-propagation (BP) neural network response surface is developed with the sample data from the FEM experiments. Further more, genetic algorithm (GA) is applied with the neural network response surface as the objective function. Finally, experimental and simulation verifications are carried out on a single stiffener specimen. The forming error of the panel formed with the optimal path is only 5.37% and the calculating efficiency has been improved by 90.64%. Therefore, this novel optimization method is quite efficient and indispensable for the press bend forming path designing.     

减震器支座冲压成型模拟分析

使用三维CAD软件UG对车用减震器支座进行三维建模,在基于一步成型法理论的Hyperform中建立了零件的有限元模型。模拟了结构的成型过程,分析了其可成型性,减薄率、应力和应变等,根据冲压工序模拟了没有中间冲孔的减震器支座的冲压成型,并与带中间孔的分析结果进行了对比,给出了最终的坯料形状,为Hyper-form应用于实际生产提供了参考依据。     

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.     

RECENT DEVELOPMENT OF PROCESS SIMULATION AND ITS APPLICATIONS TO MANUFACTURING PROCESSES

l.IntroductionThemostboortantdrivingforceinmanufacturillistoPrOduCeabetterPrOductatalowercost.GenerallyeffecthemethodsinchideshOrtenintheleadtiminthedesigncyCle,andredUcinthetoolingcostandmaChinedOWnmeatProductionst4e.AllOfthemrewtabettertmderstandingofhO…     

NUMERICAL ANALYSIS FOR VIBRATION CONTROL OF BEAMS WITH ACTIVE CONSTRAINED LAYER DAMPING TREATMENTS

IntroductionThe conventional passive constrained layerdamping (PCLD) treatments[1～ 3] are applied tomachines and structures widely over the lastcentu-ry because they are reliable and simple,however,they are not intelligent. Once the damping treat-ments are installed,they can not be adjusted andcan not adapt themselves to changeable environ-ment.Recently,active damping has received in-creasing attention in the aeronautic and astronauticindustries because of its significant and adjustabledamp…     

牵引式滑坡后缘破裂面计算方法

斜坡发生牵引式滑动破坏,形成后缘拉裂面,后缘面形态对滑坡稳定性分析及推力计算具有重要影响,但其在滑坡体内部的空间特征难以确定. 为探索后缘破裂面的形成机理和计算理论,建立合理的数学力学模型,提出后缘破裂面倾角的计算方法,确定各级滑块的最危险破裂倾角,并将其所在破裂面作为条分型式,计算各级滑块的稳定系数,实现滑坡渐进破坏过程的稳定性分析;同时,开展室内模型试验进行验证,研发了新的模型试验装置,其主体由若干渗透盒组成,能够构成各种几何形状的分段式滑面;通过向不同分段的渗透盒注水,实现牵引式滑坡的逐级失稳过程,并测试各级滑块最终形态的后缘破裂面倾角. 结果表明:后缘破裂面倾角计算值与试验值具有较高的一致性,主要集中在70° 左右,相对误差介于2%～4%之间;滑坡体失稳形成的各级滑块稳定性不同,第一级滑块的稳定程度最差,越向坡体后侧稳定性越好. 可为牵引式滑坡的稳定性分析提供新的思路.      

混凝土桥梁结构温度自应力计算方法探讨

为了更准确地计算混凝土桥梁结构的温度应力,提出了一种基于弹性理论求解温度自应力的新方法.该方法按平面应变问题求解横向温度应力,在此基础上用解析公式计算纵向温度应力.为了验证了该方法的正确性,给出了一个算例.算例表明,该方法与三维有限元法的计算结果基本相同,而基于结构力学的传统方法,计算误差最大可达30%以上.     

CRTSⅡ型轨道板翻转机主梁结构的有限元分析

通过研究CRTSⅡ型轨道板翻转机的翻转过程,结合传统翻转机的翻转过程,对传统翻转机的主梁结构进行改进。改进后的翻转机主梁采用箱式结构,这种主梁结构更紧凑,并且容易加工。对改进的翻转机主梁结构进行有限元分析,结果表明,改进后的箱式主梁结构满足强度和稳定性要求,可以实现在翻转过程中结构稳定,为主梁结构的优化设计提供依据。     

结构声辐射边界元声学灵敏度研究

声学灵敏度反应了结构振动引起的辐射声压与结构表面法向振动速度之间的关系.分析了基于边界元法的结构振动声辐射计算原理,推导了声学敏度.用有限元法计算结构动力学响应,以有限元法计算的结构振动速度为边界条件,基于边界元法计算结构振动幅射的声压及声压对振动速度的灵敏度.以一六面体的振动为研究实例,得到了其振动的外场声压及其对结构振动法向速度的灵敏度.结果表明声学灵敏度只与结构几何形状及设计域点的位置有关.     

桥梁结构非线性实体有限元建模

桥梁研究中有一些特殊的分析,不仅需要考虑结构的非线性问题,而且要用实体单元模型计算关键点处的应力-应变状态。鉴于考虑非线性的实体有限元模型在桥梁工程中应用较少,为了提高计算模型的可靠性,分析和讨论了这种有限元模型构建过程中应该注意的若干问题,包括几何模型的选择、非线性本构关系的选择、边界条件的处理、荷载的施加、单元类型的选择和网格划分、非线性算法选择等。最后基于这些探讨,以一个钢-混组合梁为例,用非线性实体有限元法对其进行了承载能力极限状态的模拟,软件的输出数据与实验实测结果吻合较好,这证明了在一些特殊的桥梁结构分析中,采用考虑非线性的实体单元模拟是可行的。