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.     

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...     

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…     

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.     

Finite Element Simulation of Processes Involving Moving Heat Sources. Application to Welding and Surface Treatment

IntroductionAwiderangeofweldingorsurfacetreatmentprocessesinvolvetheuseofaheatsourcemovingataconstantspeedoverthesurfaceofthecomPonent.ThreedimensionalcomPutationofresidualstressesanddistortionsinducedbythiskindofprocesses,usingtheusualfiniteelementmethod,needsveryrefinedmeshesinordertocorrectlydescribethepropertiesandstressgradientsintheheataffCctCdzonealongthepathoftheheatsource.Inthispaper,wediscussthedifferentnumericalaPproaches,imPlementedinSYSWELD@software,whichcanbeusedtodorealisti…     

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.     

批量生产多循环闭式冷锻铝材成形误差机械热偶合有限元分析

在冷成形加工中因为工件和模具中的温度随时间变化而使工件的成形误差也随之变化，以前的成形误差分析仅涉及单个工件加工循环。同时考虑机械效应和热力效应对成形误差的影响，对批量生产多循环闭式冷锻铝材成形过程中工件的成形误差进行了有限元分析，给出了一个包含成形各个阶段所产生的成形误差的误差分析公式。该公式可用于诸如挤压成形等其他成形工艺。这一分析工作为高精密成形误差补偿方法的研究提供了指导。     

有限元强度折减法识别滑动带的例证

以广东省西部沿海高速公路某处于挤压变形阶段的滑坡为研究对象,通过有限元强度折减法对其进行稳定性分析,判别其塑性变形区,再用物探的面波等速度彩色剖面图合成技术来实现瞬态面波勘察技术对滑动带的搜索,对比及验证有限元数值分析对滑动带的判别结果,实践证明二者所显示的滑动面数量和位置基本一致,印证了有限元强度折减法在滑坡稳定性分析中对潜在滑动面搜索的有效性及可靠性.     

Sensitivity analysis of parameters for multi-stand roll forming using a new booting model

Multi-stand roll forming is a process that has very complicated deformation behaviour and shows significant nonlinearity.In this paper, the sensitivity analysis of parameters for multi-stand roll forming was performed via a new booting finite element method(FEM) model.Compared with the most of simulation, the new model is more consistent with production process and can account for the effects of roll rotating speed.Based on the model, the process of an open section channel formed with 10 passes was simulated and the sensitivity analysis was conducted with orthogonal experiment design combined FEM model.The multi-stand roll forming process can be efficiently analyzed by the new booting model.And sensitivity analysis shows the hardening exponent plays an important role in controlling the quality of the products.     

Implementation of Heat Treatment Process Simulation with Object-Oriented Method

IntroductionDuringheatingorcoolingprocess,metallicmaterialsundergotheevoluhonsoftemPeraturefield,phasecompositionsandstrCssfield.ThereexistseveralinteaCtionsl1-4](couPlingeffeCts)betWeenthesephenomena.TodescribeallthesephysicalprocessescorrecUyandefficientiy,thefiniteelementmethodisoftenadoPtedll'5'6].Asitiswellknown,conventionalfiniteelementanalysisprogramsarecomplicatCdanderror-Prone.ComPlexcontrolanddatastructuresassociatedwithsoftwaretendtOobscurefundamerealintenhons,maldngdevelopmen…     

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.     

Modeling, identification and simulation of DC resistance spot welding process for aluminum alloy 5182

Currently the aluminum alloy resistance spot welding(AA-RSW) has been extensively used for light weight automotive body-in-white manufacturing.However the aluminum alloys such as AA5182 have inferior weldability for forming the joint due to their high reflectiveness to heat and light.Therefore it is necessary to further develop the high performance control strategy and the set-up of a new welding schedule.The welding process identification is the essential issue where the difficulty arises from the fact that the AA-RSW is a nonlinear time-varying uncertain process which couples the thermal,electrical,mechanical and metallurgical dynamics.To understand this complicated physical phenomenon a novel dual-phase M-series pseudo-random electrical pattern is adopted to excite the AA-RSW electrical-thermal process and the thermal response is recorded according to the welding power outputs.Based on the experimental information,the transfer function of an AA-RSW electrical- thermal mechanism is identified,and the optimum model order and parameters are determined.Subsequently a control-oriented DC AA-RSW model is established to explore the welding power control algorithm.The simulated results of the control model show agreement with the experimental data,which validates its feasibility for the corresponding welding control.     

内燃机活塞温度场的轴对称组合边界元分析

采用常数-线性组合边界元计算轴对称热传导问题,既可减小奇异点计算的困难性,又提高了计算精度。本文运用FORTRAN77算法语言编制了包含有三种类型边界条件在内的轴对称组合边界元分析程序,具体分析了6135ZG柴油机活塞的温度分布。结果表明,应用边界元法分析轴对称活塞温度场,计算工作量比有限元的计算量显著减少,而计算结果同有限元结果吻合得较好,与实际测量结果相比,最大相对误差仅为1％。     

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。     

几种大型风力发电机组技术特点及应用

大型风力发电机组技术不仅体现当代电机制造、材料工程、电力电子、自动控制、流体力学和地质气象等领域的科技水平,而且引领着未来风力发电机组设计制造技术的发展方向。根据发电机驱动方式的不同,风力发电机系统可分为双馈式、直驱式和半直驱式。分析3种驱动方式下各风力发电系统的技术特点及优缺点,并简要介绍各种风力发电机系统的应用状况。     

Research and Application Prospect of Computer Simulation on Heat Treatment Process

AseriesofgreatProgresseshavebeenachievedintheresearchofheattrCtoelltmathematicalmodelandcomPotersimulationduringrecellttenyears.ThecouPlingbforeentemPerthee-phasetransformation-stressl'-'],threedimensionalnon-linearFEManalysis[#-'],thecalculationofphasetransformationkinetics['-'],theeffectofstressonphasetransformationkineticsl,'-,,],thedealingwithabruPchangedboundnyconditionsl"#],thesimulationonfludfield["l,andotherinveshgationshavecarredout,andtheirachievementshaveProvidedasoundbasisfo…     

增材制造技术发展和在先进轨道交通装备中的应用展望

从增材制造技术的应用现状出发，概述了几种增材制造技术的特点和应用范围；介绍了典型的金属增材制造最新研究进展；考虑现有增材制件存在的固有缺陷、残余应力和裂纹等问题，总结了能有效改善成形增材制件质量的后处理工序；梳理了增材制件疲劳性能的影响因素，重点阐述了缺陷与增材制件疲劳损伤的关联性；探讨了增材制造技术广泛应用所涉及的关键技术；系统总结了金属增材制造技术在国内外轨道交通装备领域的应用现状。研究结果表明:由于热源和工艺参数不同，增材制造技术制备材料的组织特性和力学性能存在差异；增材制造的钛合金、铝合金以及其他前沿金属材料在轨道交通装备领域具有较好的应用前景；合理的后处理工艺可以有效控制缺陷的形成，消除残余应力，减少微裂纹；缺陷作为制约增材制造技术在制造行业应用的关键因素，研究其分布规律和探究其与疲劳性能的关系，对增材制件的疲劳性能评估有重要作用；从材料规范、成形精度、质量控制、生产效率、生产链以及无损检测技术等方面，综合增强增材制造关键技术自主创新性研发，有助于提升中国制造行业在国际上的竞争力；增材制造技术受到轨道交通行业的重视，并开始应用这种新型技术成形了金属结构件，但该技术的成熟应用仍面临许多问题，需要国内外学者进一步开展深入研究。      

Solving resource-constrained multiple project scheduling problem using timed colored Petri nets

To solve the resource-constrained multiple project scheduling problem (RCMPSP) more effectively, a method based on timed colored Petri net (TCPN) was proposed. In this methodology, firstly a novel mapping mechanism between traditional network diagram such as CPM (critical path method)/PERT (program evaluation and review technique) and TCPN was presented. Then a primary TCPN (PTCPN) for solving RCMPSP was modeled based on the proposed mapping mechanism. Meanwhile, the object PTCPN was used to simulate the multiple projects scheduling and to find the approximately optimal value of RCMPSP. Finally, the performance of the proposed approach for solving RCMPSP was validated by executing a mould manufacturing example.     

Computer Aided Simulation on Precision Cold Forging of Universal Joint Cross

IntroductionThefiwtee1emenmethod(FEM)playsanextrmelyimPortantroleintheanalysesofengineeringproblems.ForalongtimethismethodhasmainlybeenaPPliedinthelinearfieldandshownitsgreatpower.HoweveealOtofnonlinearengineeringPrOblemsWhichcanneitherbesimPlyreducedtolinearonesnorrCPresentedbylinearlyanalogywhichshallchnsethePfacticalconditionsrelativelymuch,havechallengedfiniteelementmethod(FEM).RecentymuchProgresshasbeenmadebothinthemathematicalandmechanicaltheoryandthecomPulertechnologysothatevent…