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.     

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.     

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.     

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。     

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.     

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.      

纵向冲击下高速列车车体承载极限数值模拟

进行了高速列车车体6005A-T6、6082A-T6铝合金的静态拉伸和动态压缩试验,识别了0.001~2 500 s-1应变率范围内2种铝合金的材料应变率效应,建立了对应的Johnson-Cook本构模型;构建了高速列车典型车辆的显式动力分析模型,完成了刚性墙冲击车体过程仿真,研究了车钩稳态载荷、冲击速度、加载方式对车体承载极限的影响;分析了高速列车一号车和二号车车体在冲击载荷下的变形演化,通过应力变化临界点确定了车体的承载极限,并对列车在更高能量配置模式下的车体承载性能进行了验证。研究结果表明:在0.001~2 500 s-1应变率范围内,6005A-T6和6082A-T6铝合金应变率敏感系数分别为2.9×10-3和8.5×10-3,应变率效应不明显;纵向动态冲击载荷下,应变率强化对铝合金车体结构承载力影响不明显,惯性效应是其承载能力高于静态极限的主要原因;纵向冲击载荷从车钩位置传递时,一号车和二号车车体的动态承载力水平显著高于车体许用静态压缩载荷;冲击载荷下的车体结构承载力可为高速列车碰撞各界面能量分布问题中吸能元件平台力取值提供上界;可适当考虑提高车体许用压缩载荷以扩大列车端部吸能部件力学参数设计域,以满足更苛刻需求下的列车被动安全性能。      

Dynamic investigation on composite flexible multi-body system considering thermal effect

The dynamic performance of composite flexible multi-body system under the simultaneous action of thermal fields and driving constraint is analyzed. Based on strain-displacement relation of the Mindlin plate theory which includes transverse shear deformation, and considering thermal effect, variation equations of laminated plate are derived by the principle of virtual work. The finite element method is used for discretization. According to kinematics constraint relation, dynamic equations for spatial slider-crank system are established. Simulation results show that spatial deformation (torsion deformation) appears in the multi-layered composite slider-crank mechanism which is simulated with planar motions. Furthermore, the influence of coupling between thermal expansion and flexible deformations of non-symmetrical composite plates on the large overall motion under the uniform temperature field is investigated. Finally, significant change in constraint force due to the spatial deformation is shown.     

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.     

地震边坡稳定分析方法综述

根据地震对边坡的作用不同 ,地震边坡失稳分为 :惯性失稳和衰减失稳 .惯性失稳的分析方法有拟静力法、Newmark滑块分析法、有限元方法及概率分析法等 .而衰减失稳的分析方法有流动破坏分析法和变形破坏分析法等 .本文对这些分析方法的发展、应用及特点进行了综述 ,提出了地震边坡分析中主要研究内容、存在的问题及发展趋势     

Nonlinear Dynamic Buckling of Damaged Composite Cylindrical Shells

Based on the first order shear deformation theory(FSDT), the nonlinear dynamic equations involving transverse shear deformation and initial geometric imperfections were obtained by Hamilton's philosophy. Geometric deformation of the composite cylindrical shell was treated as the initial geometric imperfection in the dynamic equations, which were solved by the semi-analytical method in this paper. Stiffness reduction was employed for the damaged sub-layer, and the equivalent stiffness matrix was obtained for the delaminated area. By circumferential Fourier series expansions for shell displacements and loads and by using Galerkin technique, the nonlinear partial differential equations were transformed to ordinary differential equations which were finally solved by the finite difference method. The buckling was judged from shell responses by B-R criteria, and critical loads were then determined. The effect of the initial geometric deformation on the dynamic response and buckling of composite cylindrical shell was also discussed, as well as the effects of concomitant delamination and sub-layer matrix damages.     

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.     

数值模拟法确定饱和土强夯施工参数

探讨了用数值模拟确定饱和地基土强夯的施工参数方法:根据孔隙水压力增量随夯击次数的变化情况确定强夯的最佳夯击次数;根据孔隙水压力消散情况确定强夯的间歇时间;根据土体沿深度方向的竖向变形确定土体有效加固深度;根据沿水平方向的竖向变形确定强夯的单点加固范围。研究结果为强夯设计和加固效果评价提供有力的依据。     

冲压焊接离心泵的结构分析与设计

通过对多级离心泵的性能结构进行分析,基于冲压工艺设计出冲压焊接多级离心泵的基本构成,讨论了部分零件的主要结构及其冲压工艺过程,最后将零件进行焊接并装配成完整的冲压焊接多级离心泵.并对其叶轮内流体进行CFD静压力场分析.     

模锻件切边变形问题分析及改进

分析了汽车发动机连杆锻件工字形截面在切边过程的“八字”变形、直轴类锻件切边时轴线弯曲及薄齿轮类锻件冲切时平面变形产生的原因,提出了相应的模具改进措施。     

带约束的动态Delaunay三角剖分算法研究

根据传统的三角网格生长算法和数据点渐次插入算法,改进了带约束的动态Delaunay三角剖分算法,进一步得到了优化三角网格的动态三角剖分算法,改进了以往三角剖分算法必须知道所有顶点后才能进行剖分的缺点,并引入合理的约束边插入算法,使得最终三角网格达到最优.     

交通荷载下道面与软土地基协同工作分析

对交通荷载作用下道面和软土地基协同工作研究现状进行了探讨,分析了荷载的动力特性和循环特性以及地基的弹粘塑性问题,采用弹粘塑性动力有限元法和模型试验对这一问题进行了研究,得到了道面的应力、弯沉和变形特性.     

Substructuring technique for dynamics analysis of flexible beams with large deformation

In this paper, the substructuring technique is extended for the dynamics simulation of flexible beams with large deformation. The dynamics equation of a spatial straight beam undergoing large displacement and small deformation is deduced by using the Jourdain variation principle and the model synthesis method. The longitudinal shortening effect due to the transversal deformation is taken into consideration in the dynamics equation. In this way, the geometric stiffening effect, which is also called stress stiffening effect, is accounted for in the dynamics equation. The transfer equation of the flexible beam is obtained by assembling the dynamics equation and the kinematic relationship between the two connection points of the flexible beam. Treating a flexible beam with small deformation as a substructure, one can solve the dynamics of a flexible beam with large deformation by using the substructuring technique and the transfer matrix method. The dynamics simulation of a flexible beam with large deformation is carried out by using the proposed approach and the results are verified by comparing with those obtained from Abaqus software.     

受冲薄壳弹塑性大变形力学特性的有限元分析

采用基于堕劝坐标系的假设应变场壳单元,弹塑性等向强化材料模型,一体化接触搜寻算法,罚参数接触力计算法及显式时间积分格式进行薄壳弹塑性大变形力学特性分析。算例表明,该方法简明,直观,快捷,方便。     

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…