拼焊板U形件弯曲成形回弹补偿和焊缝移动规律研究

为了提高预测回弹的准确性,选用了拼焊板U形件作为研究对象,运用Dynaform软件,进行冲压成形和回弹的有限元数值模拟研究,得出了压边力、板料强度以及板料厚度对焊缝移动的影响规律,并探讨了焊缝、压边力、材料性能参数和板料厚度对回弹的影响,最终进行回弹补偿与实验验证.研究结果表明随着压边力的增大,焊缝向厚侧移动;板料强度不同时,焊缝向强度高的一侧移动;厚度不同时,焊缝向板料厚的一侧移动;焊缝会令板料的回弹量增大;随着压边力的增大,回弹量减小;弹性模量相同的条件下,材料屈服极限σs越高,回弹角越大;材料硬化指数n越小,回弹角越大;保持厚侧板料不变的情况下,另一侧板料越薄,回弹量越大.     

变径管内高压成形的厚度分界圆

为了研究变径管内高压成形过程中工艺参数和管坯几何尺寸对壁厚分布的影响,通过力学分析和全量本构方程,推导出变径管内高压成形厚度分界圆的解析公式.该公式反映了摩擦系数、膨胀系数、管端轴向应力与内压之比、送料区相对长度、管坯相对壁厚、零件过渡锥角等参数与厚度分界圆相对位置之间的定量关系,并与数值模拟规律一致.研究表明:随着摩擦系数、管端轴向应力与内压之比、送料区相对长度的增加,壁厚不变的厚度分界圆距离管端越来越近,即膨胀区壁厚减薄区域是越来越大的;而随着管坯相对壁厚的增加,壁厚不变的厚度分界圆距离管端越来越远,即膨胀区壁厚减薄区域是越来越小的.     

低碳钢薄壁焊管液压胀形行为

为了研究焊管液压胀形过程的变形行为,在管材胀形性能测试系统上进行了不同长径比条件下低碳钢(STKM11A)薄壁焊管的胀形实验,获得了焊管的壁厚分布规律、胀形区轮廓形状、极限膨胀率和应变分布规律。结果表明:管材焊缝区的减薄率仅为2.4%~5.5%,等效应变仅为0.05~0.10,变形程度相对母材区较小,主要发生几何位置移动。环向壁厚的最薄点位于以焊缝为中心的对称两侧士30°位置处。随着胀形区长度增大,管材破裂压力、减薄量、极限膨胀率均发生减小,胀形区轮廓逐渐偏离椭圆形,当长径比达到2.0时,已不再适合用椭圆函数描述。此外,胀形区长度增大过程中,管材从双拉向平面应变状态发生转变,在此基础上建立了焊管的成形极限图。     

基于灰色关联分析的轧制差厚板盒形件充液拉深成形工艺参数多目标优化

目的 将充液拉深工艺引入轧制差厚板零件的成形,为了进一步掌握差厚板的充液拉深成形性能,对差厚板盒形件充液拉深成形过程进行研究。方法 通过理论推导获取临界液池压力公式,在此基础上运用数值模拟方法分析液池压力比对差厚板厚度减薄率和厚度过渡区移动量的影响,采用正交试验和灰色关联分析获取成形参数对差厚板盒形件成形性能的影响规律和最优参数组合,实现对差厚板盒形件充液拉深成形工艺参数的多目标优化。结果 随着薄-厚侧液池压力比的增大,差厚板最大厚度减薄率先减小后增大,过渡区移动量先增大后趋于平稳,薄-厚侧液池压力比为2较为合理。厚侧压边力、摩擦因数、薄-厚侧液池压力之比、薄-厚侧压边力之比、厚侧液池压力对差厚板盒形件充液拉深性能的影响程度依次减小。结论 采用灰色关联分析得到的最优工艺参数组合来完成差厚板盒形件的充液拉深成形,能够有效地抑制差厚板零件厚度的过分减薄及厚度过渡区的过度移动,进而提高差厚板的成形性能。     

拼焊板焊缝方向对其单向拉伸性能的影响研究

为提高拼焊板成形性,用单拉实验来研究拼焊板焊缝方向对其拉伸性能的影响.采用解析、实验和有限元法研究了拼焊板焊缝方向对其综合延伸率、失效模式的影响.结果表明,当焊缝角度较小时,失效表现为焊缝开裂;随着焊缝角度增大,平均延伸率非线性减小,且变化速率逐渐减小.当焊缝角度超过一定值后,失效变为薄侧母材开裂,并随着焊缝角度增大拼焊板综合延伸率逐渐增大,且增大的速率逐渐减小.在失效模式转换时,焊缝角度相应存在一个临界点,这一临界角度大小主要依赖于焊缝和薄侧母材性能.适当的焊缝角度有利于拼焊板成形性能的提高和失效模式的控制.     

锥形件变薄旋压回弹的三维有限元分析

了解锥形件变薄旋压成形后的回弹规律,对提高旋压件的成形质量有重要意义.分别采用动态显式和静态隐式方法建立了锥形件变薄旋压及回弹的三维有限元模型,并研究了芯模转速和旋轮进给比对回弹前后应力、应变及壁厚变化和零件形状的影响.研究表明:随芯模转速增加和旋轮进给比减小,回弹前后最大等效应力差逐渐减小,塑性应变差及壁厚变化基本不变;回弹后最大偏离量随芯模转速和旋轮进给比增大在芯模转速较小时变化不大,而在其较大时随其增大有所减小,并随旋轮进给比增大呈先减小后增大再缓慢减小的趋势.     

弯管壁厚减薄与材料特性关系的试验研究

在管材弯曲变形的系列研究中,为了分析导致弯管外侧壁厚减薄的各种影响因素,及材料机械性能对管材弯曲成形性及其各种成形缺陷产生的影响,进行了管材状态下的材料拉伸实验,其结果与同种材料的标准拉伸实验得到的性能参数相比,有一定差异.针对1C18Ni9Ti管材性能参数与部分弯曲实验结果进行的比较和定性分析表明,无论弯管外侧材料处于单向或双向不等拉伸状态,管壁厚减薄量都随材料的硬化指数和延伸率增大而增加,且随材料的屈强比增大而减小.     

薄板剪应力起皱研究

以Hill关于弹塑性失稳理论为基础,建立了剪应力起皱失稳的速度场分布,给出了临界起皱剪应力理论计算结果,分析了板料屈服强度、硬化指数、板厚方向性指数及板料厚度对临界剪应力的影响,并与实验和数值模拟结果进行了对比。研究表明:薄板在剪应力作用下可以产生起皱,临界剪应力理论计算、实验及数值模拟结果基本相符,临界剪应力随屈服强度σs减小、硬化指数n值的增大、板厚方向性指数r值的增大、板料厚度t的增大而增大。     

激光拼焊板拉延成形焊缝移动优化控制

针对不同材料种类、厚度、强度、镀层焊接的拼焊板存在的成形问题,采用有限元仿真技术准确预测了拼焊板拉延成形工序的金属流动,在此基础上开展了拉深筋优化工艺研究.研究结果表明:由于纵梁前端和后端变形不均匀,拼焊板焊缝在拉延过程中随着拉深筋设置的不同产生不同的流向;当纵梁后端两侧拉延筋阻力系数分别设置为0.35和0.15时,零件内部焊缝移动量最小,更有利于拼焊板的成形质量控制.     

焊缝强度对薄壁焊管绕弯起皱及壁厚的影响

在薄壁焊管绕弯成形中,焊管起皱及壁厚分布受焊缝相对基体材料强度的影响.提出了焊缝相对强度因子Sf的概念,以反映焊缝相对于基体材料的强弱性,并推导了其解析表达式,给出了适用于焊管的起皱趋势判断公式.同时,基于有限元模拟,分析了焊缝相对强度因子对焊管绕弯成形过程中起皱及壁厚变化的影响规律.研究表明:1)当焊缝相对强度因子S...     

Influence of forming effects on the axial crush response of hydroformed aluminum alloy tubes

The impact behaviour of tubular hydroformed axial crush tubes is examined. The results of dynamic axial crush tests performed with both non-hydroformed and hydroformed AA5754 aluminum alloy tubes were compared to predictions from finite element models. Explicit dynamic finite element simulations of the hydroforming and crash events were carried out with particular attention to the transfer of forming history from the hydroforming simulations to the crash models. The values of tube thickness, work hardening, and residual stresses at the end of the hydroforming simulations were used as the initial state for the crash models. In general, simulations performed using the von Mises yield criterion with isotropic material behaviour gave reasonable predictions when compared to experimental data. It was found that it was important to account for the forming history of the hydroforming operation in the axial crush models. The results showed that work hardening resulting from hydroforming is beneficial to increasing the energy absorption during crash, whereas thickness reduction decreased the energy absorption. Residual stresses had little effect on the energy absorption characteristics. It was also shown that the energy absorption characteristics of tubes with the same mass could vary greatly by adjusting the geometry of the tube and the amount of work hardening experienced by the tube during hydroforming.     

Crashworthiness of straight section hydroformed aluminium tubes

There exists considerable motivation to reduce vehicle weight through the adoption of lightweight materials, such as aluminium alloys, while maintaining energy absorption and component integrity under crash conditions. The interaction between tube hydroforming and behaviour during crash events was studied using lightweight automotive structural members. Dynamic crush tests were performed on 400 mm length sections of both non-hydroformed and hydroformed EN-AW 5018 aluminium alloy tubes. The force versus crush distance data from 76.2 mm diameter non-hydroformed tubes was compared with results from 76.2 mm square cross-section hydroformed tubes of 2.0 and 3.5 mm initial tube thicknesses. The hydroforming operation was performed using a high-pressure process in which the corner radius of the tube cross-section was varied. Explicit dynamic finite element simulations of the hydroforming and crash events were carried out with particular attention to the transfer of forming history from the hydroforming simulations to the crash models. The values of the tube thickness, work hardening, residual stress, and damage level at the end of the hydroforming simulation were used as the initial state for the crash model. The Gurson–Tvergaard–Needleman constitutive model was used to account for damage based on void nucleation, growth, and coalescence. Numerical predictions of the force versus crush distance response were compared to experimental data. The results have demonstrated that it is important to account for thickness changes and work hardening from previous forming operations, in simulating crash events. The energy absorbing capabilities of the hydroformed aluminium tubes decreased with sharper corner radius due to increased thinning of the material during the hydroforming process. It was found that the simulations slightly over-predicted the mean crush force compared to the experimental data.     

Effects of friction on roller expanded tube–tubesheet joint strength

Roller expansion of new tubes in enlarged heat exchanger tubesheet holes requires higher rolling torques which may result in over-thinning of the tube wall. This affects adversely the tube–tubesheet joint strength, which is measured in terms of residual contact pressure between the expanded tube and tubesheet. The axial force required to cause the mechanical failure of the tube–tubesheet joint has therefore been considered as an indication of the integrity of the joint. This force is influenced by several parameters such as the type of tube and tubesheet materials, the initial clearance and coefficient of friction. In the present work, an axisymmetric finite element (FE) model is used to evaluate the combined effects of friction between tube and tubesheet, initial clearance and tube material strain hardening on the strength of the tube–tubesheet joint. The FE results show that the increase in friction between tube and tubesheet results in higher residual contact stress and lower cutoff clearances. The residual contact stress also increased linearly with increasing tube material strain hardening level for all friction coefficients.     

内压对镁合金差温内压成形起皱行为的影响

针对镁合金管材热态内压成形存在的壁厚不均、膨胀率小等问题,本文提出利用温度差控制变形的差温内压成形新方法,沿管材轴向建立了具有不同温度梯度的温度场,开展非均匀温度场作用下的镁合金管材塑性失稳起皱行为研究,研究了内压对镁合金差温内压成形起皱参数的影响规律。当恒定内压8MPa时,成形后形成均匀的三个皱纹;采用线性增加的内压补料,成形后仅形成均匀的两个皱纹。恒定内压下轴向补料有助于形成更均匀的多点起皱,变内压轴向补料会改变起皱临界条件,提高了成形区材料的稳定性,抑制后续皱纹的形成。     

FEA comparison of high and low pressure tube hydroforming of TRIP steel

The increasing application of hydroforming for the production of automotive lightweight components is mainly due to the attainable advantages regarding part properties and improving technology of the forming equipment. However, the high pressure requirements during hydroforming decreases the costs benefit and make the part expensive. Another requirement of automotive industries is weight reduction and better crash performance. Thereby steel industries developed advanced high strength steels which have high strength, good formability and better crash performance. Even though the thickness of the sheet to form the component is reduced, the pressure requirement to form the part during expansion is still high during high pressure hydroforming. This paper details the comparison between high and low pressure tube hydroforming for the square cross-section geometry. It is determined that the internal pressure and die closing force required for low pressure tube hydroforming process is much less than that of high pressure tube hydroforming process. The stress and thickness distribution of the part during tube crushing were critically analysed. Further, the stress distribution and forming mode were studied in this paper. Also friction effect on both processes was discussed.     

Experimental and numerical assessment of mechanical properties of welded tubes for hydroforming

The identification of welded tubes properties considering the weld bead and Heat Affected Zone (HAZ) is important for reliable and accurate finite element simulation of tubular plastic forming processes such as tube hydroforming and rotary draw bending processes. Therefore, a simplified method is proposed to extract the weld bead and HAZ properties. Full size standard tensile specimens cut from the welded tube and comprising the weld parallel to the load direction are extended to failure. Mechanical properties obtained from uniaxial tensile test are correlated with the microhardness data measured across the welded specimen and by using the rule of mixtures; the constitutive model parameters of weld bead and HAZ regions are identified. Accuracy of the proposed method is assessed by comparing finite element simulation predictions to experimental measurements obtained from two mechanical tests: the first one is the uniaxial tensile test performed on specimens comprising the weld line perpendicular to the loading direction and the second test is the free bulge hydroforming test achieved on seamed tubular samples. This investigation has shown that the presented method is practical in use and sufficiently accurate to extract the weld metal properties of seamed tubes.