金属板材单点渐进成形数值模拟及机理研究
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摘要
金属板材单点渐进成形是一种新型的金属板材数控无模成形技术,是升级传统手工钣金工艺的现代化加工方法。这种成形工艺能够柔性化、低成本、方便快捷地加工出复杂的壳体零件。同时,与传统冲压工艺需要大批量制造以保证成本经济性不同,该工艺适宜于小批量灵活加工,因此,更能满足现代市场日益迫切地个性化生产需求。
金属板材单点渐进成形工艺在应用中还存在一些迫切需要解决的问题,如何合理选择工艺参数、如何避免成形中的破裂等。要解决这些问题,就需要对金属板材单点渐进成形的变形机理进行深入研究。在常规的物理实验研究中,难以直接获得成形过程中详细的应力、应变等力学参量,仅由间接测量获得的局部数据不能客观全面的反映出渐进成形过程的变形机理。而通过有限元法数值模拟,可以直接、方便、直观地获得这些有价值的数据,应用于成形机理研究。在常规的板材成形工艺研究中,有限元法数值模拟已发挥出举足轻重的作用。
金属板材单点渐进成形由于自身的特点,如成形过程载荷加载轨迹复杂且长、板材厚度的剧烈减薄变化、以及局部变形累积等,使得对其进行有限元法数值模拟存在建模难度大、计算效率低等难点问题。
本课题首先基于非线性、弹塑性有限元理论方法,对金属板材单点渐进成形过程的数值模拟的建模方法进行研究。通过建立能够描述邻接单元厚度连续变化的八节点六面体实体单元、涉及材料各向异性的非线性弹塑性材料模型、和工具头运动轨迹动态加载的控制策略等数值模拟中的关键性问题,对适用于金属板材单点渐进成形数值模拟分析的有限元模型的建立进行合理规划。
根据建模规划,对渐进成形实验中最具代表性的方锥台件和圆锥台件,各自建立两种类型的有限元分析模型,即完整有限元分析模型和局部有限元分析模型。完整有限元分析模型是建立在对渐进成形过程边界条件、力学关系等的真实仿真基础上,而为了提高模拟效率建立的局部有限元分析模型,是通过添加虚拟的边界约束而仿真成形过程。通过四个模型的模拟结果与实验结果的对比研究表明,两类模型均适用于渐进成形的数值模拟分析,其中,方锥台件的局部有限元分析模型具有最高的计算效率。
基于完整有限元分析模型对渐进成形过程的各阶段进行分析,从而全面认识渐进成形的特点;基于方锥台件局部有限元分析模型,并将板材厚度方向的单元细分为三层,通过成形过程仿真,获取成形中,板材不同区域的应力、应变情况,提出并建立分区域的渐进成形机理解释,即,在不同区域,板材的变形方式是不同的,其中,对体现渐进成形主要特点的方锥台件和圆锥台件的侧壁充分变形区域,其变形方式是拉伸-弯曲复合变形。
基于方锥台件局部有限元分析模型,对不同工艺参数下的成形过程进行仿真,研究工艺参数板材厚度变化、塑性变形区、以及成形力等的影响关系。从而为渐进成形中合理选用工艺参数提供依据。
最后,在渐进成形数值分析的基础上,探讨了对工具头磨损进行数值模拟分析的方法和流程,并通过仿真,研究了工艺参数对工具磨损的影响关系。
Single Point Incremental Forming Process (SPIF) is an innovative sheet metal forming technology without dedicated dies used to improve the traditional sheet metal process. By this method, complex shell parts could be manufactured with flexibility, cost reduction and convenient. Traditional stamping processes require the manufacture of large bathches in order to ensure economy of production. But SPIF is suitable to produce very small lot of batches economically and quickly to overcome the market growing demands of highly customized products.
In the application, SPIF still exist some of the pressing need to address the question of how to select the correct technical parameters and how to avoid cracking in the forming. To solve these problems, the deformation mechanism of SPIF should be studied seriously. By conventional physics experiments, detailed information such as stress distrubution, strain and other mechanical parameters could’t achieved directly. And it’s not objective and comprehensive to understand the deformation mechanism of SPIF by indirect measurement of the partial data. Finite element method (FEM) adopted by the numerical simulation can be direct, convenient and intuitive access to these valuable data used in the studing of forming mechanism. In the conventional sheet metal forming technology research, FEM has played an important role.
In SPIF process, the loading trajectory is complex and long, the thinning of the sheet thickness is dramatic, and the local deformations are accumulated. So, there are some difficutis in the numeriacla simulation of SPIF. For example, the modeling of SPIF is difficult and the computational efficiency is low.
Based on the nonlinear, elastic-plastic finite element method theory, the modeling approach of the numerical simulatioin of SPIF was studied firstly in this project. Through the establishment of the eight-node hexahedral elements describing continuous variation of the thickness of adjacent elements, the involved nonlinear anisotropic elasto-plastic material model, the control strategies of the dynamic load of trajectories and so on, the FEM model of SPIF was reasonable planed.
According to modeling planning, the most representative parts as the truncated cone and the truncated pyramid were used to modling, and each has been established two types of finite element analysis model, that is, the whole part FEM analysis model (WM-Model) and selected partical part FEM analysis model (SM-Model). WM-Model is established based on the realy situation of SPIF process, but SM-mdoel is established throuth adding suppositional bundary conditions. Through the comparative study of the four model simulation results and experimental results, it showed that the two types of models are applicable to the incremental forming the numerical simulation analysis, in which the cone-of the local finite element analysis model with the highest efficiency.
Based on the WM-model, the various stages of SPIF process was studied and the forming characters have been realized. Based on the SM-model of the truncated cone, the blank thickness element was sub-meshed into three levels. And through the forming simulation of the process, access to the plate stress and strain of the different regions in forming, and proposed the establishment of a sub-regional mechanism to explain the incremental forming, that is, in different regions, sheet deformation is different. In the main region which reflects the major character of SPIF, the deformation pattern is the composition of bending and extrusion.
Based on the SM-model of the truncated pyramid, the SPIF processes with different parameters were simulated. And the process parameters on changes in the thickness, plastic deformation region, forming force and so on were reseached. Thus, provide a reasonable basis for the selection of process parameters.
Finally, the numerical simulation approach of tool wear was studid on the basis of numerical simulation of SPIF, and the process parameters on the impact of the tool wear were researched.
金属板材单点渐进成形工艺在应用中还存在一些迫切需要解决的问题,如何合理选择工艺参数、如何避免成形中的破裂等。要解决这些问题,就需要对金属板材单点渐进成形的变形机理进行深入研究。在常规的物理实验研究中,难以直接获得成形过程中详细的应力、应变等力学参量,仅由间接测量获得的局部数据不能客观全面的反映出渐进成形过程的变形机理。而通过有限元法数值模拟,可以直接、方便、直观地获得这些有价值的数据,应用于成形机理研究。在常规的板材成形工艺研究中,有限元法数值模拟已发挥出举足轻重的作用。
金属板材单点渐进成形由于自身的特点,如成形过程载荷加载轨迹复杂且长、板材厚度的剧烈减薄变化、以及局部变形累积等,使得对其进行有限元法数值模拟存在建模难度大、计算效率低等难点问题。
本课题首先基于非线性、弹塑性有限元理论方法,对金属板材单点渐进成形过程的数值模拟的建模方法进行研究。通过建立能够描述邻接单元厚度连续变化的八节点六面体实体单元、涉及材料各向异性的非线性弹塑性材料模型、和工具头运动轨迹动态加载的控制策略等数值模拟中的关键性问题,对适用于金属板材单点渐进成形数值模拟分析的有限元模型的建立进行合理规划。
根据建模规划,对渐进成形实验中最具代表性的方锥台件和圆锥台件,各自建立两种类型的有限元分析模型,即完整有限元分析模型和局部有限元分析模型。完整有限元分析模型是建立在对渐进成形过程边界条件、力学关系等的真实仿真基础上,而为了提高模拟效率建立的局部有限元分析模型,是通过添加虚拟的边界约束而仿真成形过程。通过四个模型的模拟结果与实验结果的对比研究表明,两类模型均适用于渐进成形的数值模拟分析,其中,方锥台件的局部有限元分析模型具有最高的计算效率。
基于完整有限元分析模型对渐进成形过程的各阶段进行分析,从而全面认识渐进成形的特点;基于方锥台件局部有限元分析模型,并将板材厚度方向的单元细分为三层,通过成形过程仿真,获取成形中,板材不同区域的应力、应变情况,提出并建立分区域的渐进成形机理解释,即,在不同区域,板材的变形方式是不同的,其中,对体现渐进成形主要特点的方锥台件和圆锥台件的侧壁充分变形区域,其变形方式是拉伸-弯曲复合变形。
基于方锥台件局部有限元分析模型,对不同工艺参数下的成形过程进行仿真,研究工艺参数板材厚度变化、塑性变形区、以及成形力等的影响关系。从而为渐进成形中合理选用工艺参数提供依据。
最后,在渐进成形数值分析的基础上,探讨了对工具头磨损进行数值模拟分析的方法和流程,并通过仿真,研究了工艺参数对工具磨损的影响关系。
Single Point Incremental Forming Process (SPIF) is an innovative sheet metal forming technology without dedicated dies used to improve the traditional sheet metal process. By this method, complex shell parts could be manufactured with flexibility, cost reduction and convenient. Traditional stamping processes require the manufacture of large bathches in order to ensure economy of production. But SPIF is suitable to produce very small lot of batches economically and quickly to overcome the market growing demands of highly customized products.
In the application, SPIF still exist some of the pressing need to address the question of how to select the correct technical parameters and how to avoid cracking in the forming. To solve these problems, the deformation mechanism of SPIF should be studied seriously. By conventional physics experiments, detailed information such as stress distrubution, strain and other mechanical parameters could’t achieved directly. And it’s not objective and comprehensive to understand the deformation mechanism of SPIF by indirect measurement of the partial data. Finite element method (FEM) adopted by the numerical simulation can be direct, convenient and intuitive access to these valuable data used in the studing of forming mechanism. In the conventional sheet metal forming technology research, FEM has played an important role.
In SPIF process, the loading trajectory is complex and long, the thinning of the sheet thickness is dramatic, and the local deformations are accumulated. So, there are some difficutis in the numeriacla simulation of SPIF. For example, the modeling of SPIF is difficult and the computational efficiency is low.
Based on the nonlinear, elastic-plastic finite element method theory, the modeling approach of the numerical simulatioin of SPIF was studied firstly in this project. Through the establishment of the eight-node hexahedral elements describing continuous variation of the thickness of adjacent elements, the involved nonlinear anisotropic elasto-plastic material model, the control strategies of the dynamic load of trajectories and so on, the FEM model of SPIF was reasonable planed.
According to modeling planning, the most representative parts as the truncated cone and the truncated pyramid were used to modling, and each has been established two types of finite element analysis model, that is, the whole part FEM analysis model (WM-Model) and selected partical part FEM analysis model (SM-Model). WM-Model is established based on the realy situation of SPIF process, but SM-mdoel is established throuth adding suppositional bundary conditions. Through the comparative study of the four model simulation results and experimental results, it showed that the two types of models are applicable to the incremental forming the numerical simulation analysis, in which the cone-of the local finite element analysis model with the highest efficiency.
Based on the WM-model, the various stages of SPIF process was studied and the forming characters have been realized. Based on the SM-model of the truncated cone, the blank thickness element was sub-meshed into three levels. And through the forming simulation of the process, access to the plate stress and strain of the different regions in forming, and proposed the establishment of a sub-regional mechanism to explain the incremental forming, that is, in different regions, sheet deformation is different. In the main region which reflects the major character of SPIF, the deformation pattern is the composition of bending and extrusion.
Based on the SM-model of the truncated pyramid, the SPIF processes with different parameters were simulated. And the process parameters on changes in the thickness, plastic deformation region, forming force and so on were reseached. Thus, provide a reasonable basis for the selection of process parameters.
Finally, the numerical simulation approach of tool wear was studid on the basis of numerical simulation of SPIF, and the process parameters on the impact of the tool wear were researched.
引文
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