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.     

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.     

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.     

金属焊接毛坯冲压成形残余应力的试验研究

论述了焊接，冲夺加工中残余应力的产生过程，测试了金属焊接毛坯冲压成形的残余应力，并对试验结果进行了分析。     

Application of Decision Tree Algorithm in Stamping Process

Introduction Learning is the main symbol of human intelli-gence and the basic means to acquire the knowl-edge. Machine learning can extract the rules hid-den in data through analyzing the relations amongobjects, which is also computational theory to in-vestigate learning. Nowadays, various methodsare adopted in machine learning field, such as deci-sion tree, Bayesian classification, neural network,genetic algorithm and rough set[1]. Many machinelearning methods have been used as the convenien…     

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.     

Influence of high frequency vibration on deep drawing process of AZ31 sheet at room temperature

Quasi-ultrasonic vibration with a frequency of 15 kHz and a maximum output of 2 kW was imposed on the deep drawing process of AZ31 magnesium alloy sheet at room temperature, in order to reveal the effect of high frequency vibration on deformation behavior of AZ31 during the process. From the drawn results and the observation of the microstructure within the large deformation area, high frequency vibration has a great influence on the formability, the forming load and the failure mode of AZ31 sheet during the deep drawing process; the influence is a comprehensive result of so-called ??volume effect?? and ??surface effect??, and relies on the vibrating amplitude. Total forming load decreased significantly as soon as the vibration superimposed. According to the tensile test results of AZ31 bars under ultrasonic vibration, the formability of AZ31 sheet increases firstly with the increase of stimulating energy, then decreases and finally becomes brittle. Under the combined influence of ??surface effect?? and the ??softening?? in the ??volume effect?? near the relative low amplitude of 25%A in the experiment (A is the maximum amplitude), the formability of AZ31 reaches the largest value, and the samples possess the same distribution trend of cracks as those added with lubricating oil. With the increase of excitation energy, the ??volume effect?? gradually becomes apparent, and finally the ??hardening?? of the ??volume effect?? occupies a dominant position.     

突缘叉模锻件折叠缺陷分析

通过对缺陷的内部结构进行分析,发现突缘叉锻件法兰底面产生缺陷的主要原因是模锻前制坯工艺不合理,造成模锻时金属回流,产生折叠.提出改进制坯工艺消除锻件的缺陷的方案,经工艺和生产验证,消除了锻件缺陷,提高了锻件质量,取得满意效果,该工艺的成功应用,可为同类型产品的生产提供借鉴.     

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.     

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。     

铁路罐车封头冲压成形研究

为保证某型铁路罐车封头冷冲压成形质量,设计了具有圆形拉延筋、矩形拉延筋和不设置拉延筋3种结构形式的拉延模具型面;使用有限元方法,对3种模具结构形式下封头的冲压成形过程进行模拟分析,对比了封头起皱趋势、 成形回弹和料厚变化等模拟结果,并根据仿真结果选择合理的模具结构形式进行了试验.研究结果表明:采用矩形拉延筋进行封头冲压成形,能更有效的避免封头出现起皱、鼓包等成形缺陷,而且成形后回弹量较小;矩形拉延筋模具冲压试验所得封头无成形缺陷,测得封头最小料厚为9.6 mm,最大料厚为10.5 mm,与模拟结果基本一致;采用矩形拉延筋模具进行该型封头冷冲压成形是有效的.      

Galling failure analysis in sheet metal forming process

Galling is a known failure mechanism in sheet metal forming operations,and it can lead to fracture of the products and jamming of the tool. The temperature field and normal contact pressure distributions of the tool and the blank were studied with a finite element analysis model under the action of different blank holder force and frictional coefficient. A series of forming tests of the high strength steel were conducted to validate the finite element model. The characteristics of galling failure,the damage...     

智能冲模CAD系统中的CBD方法研究

介绍了实例推理方法（CBR）的一般原理，通过对比冲模设计过程和CBR方法，说明了基于实例的设计（CBD）方法用于智能冲模CAD系统的合理性，并研究了其中的关键技术。     

基于刚度等效模型的减重孔板结构快速分析方法

为了能够更有效率地对减重孔板结构进行计算分析, 提出一种快速分析方法; 研究了减重孔板结构模型与平面板结构模型间的一般刚度等效关系, 建立了减重孔板孔径、孔距与相应平面板等效杨氏模量、等效板厚间的关系表达式, 以等效平面板结构模型代替原孔板结构模型进行变形分析; 将局部节点位移施加到相应目标孔位模型上, 计算了目标孔位区域的应力分布; 结合试验与仿真验证了方法的准确性; 通过对某实际减重孔板结构施加不同载荷, 对刚度等效关系的稳定性进行了验证; 通过某车体底架带孔板结构实例, 对方法应用于实际工程中的有效性进行了验证。分析结果表明: 与试验结果相比, 快速分析方法仿真变形最大误差约为3%, 应变的最大误差约为5%;不同载荷下的等效杨氏模量偏差约为2.5%, 等效板厚的偏差约为1.3%;快速分析方法对变形与局部应力的平均计算误差小于6.7%, 计算时间缩短了约50%。可见, 快速分析方法可以替代传统方法对减重孔板结构进行性能分析。      

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.     

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.     

5CrNiMo钢锻模液态模锻工艺试验

采用液态模银代替自由锻造生产转向螺母5CrNiMo锻模，给出了其下模结构设计参数，介绍了5CrNiMo合金液态模锻工艺参数取位范围，分析了制件的质量。     

Compliant assembly modeling and deformation analysis considering macro residual stress in engineering component

Based on the manufacturing history chain, a component's macro residual stress is introduced to the subsequent assembly model. In the simulated method, the simulation cost is saved via mapping the bulk stress profile directly to the component compared to our previous study. It thus facilitates the finite element analysis(FEA) which takes the component location in blank and the thickness of blank as two influence parameters. The methodology is proved to be feasible by the validation experiment designed for a typical assembly structure from the aerospace industry. The results show that the bulk stress originating from material preparation affects the downstream large-scale assembly deformation. The investigation of this research helps systematically to improve compliant assembly precision.     

面向自动装配的冲模装配建模与规划

通过对冲裁模设计过程中产生的零件之间装配关系的记录，建立了冲模装配体装配关系图。以装配图为基础，根据冲模生产过程中的设计惯例和零件之间的联接关系，对构成冲模结构的各零部件进行了子装配体的划分，形成了具有层次化结构的装配体结构树，并在此基础上，通过实例说明了子装配体的装配顺序规划方法。