超高强钢 QP980 液压成形 B 柱仿真及试验研究

目的研究超高强钢QP980液压成形汽车B柱的可成形性。方法基于Autoform有限元模拟软件,仿真对比了宝钢第三代超高强钢QP980及当前广泛应用的DP980超高强钢液压成形B柱的可成形性,通过试验试制了QP980液压成形B柱,并与仿真结果进行对比。结果在相同工艺条件下,QP980具有较高安全裕度,DP980具有开裂风险,采用2种材料模拟壁厚减薄率及回弹趋势一致,DP980壁厚减薄率大于QP980,QP980回弹大于DP980;QP980液压成形B柱模拟及试验对比显示,壁厚减薄率和回弹变化趋势一致,试验壁厚减薄率大于模拟,样件实际回弹小于模拟,QP980液压成形B柱实测最大壁厚减薄率7.6%,一端施加约束,另一端回弹约6 mm。结论超高强钢QP980液压成形B柱成形性良好,满足零件性能要求。     

基于零件应用的第3代高强钢——QP钢的成形特性

目的研究第3代高强钢——QP钢在实际零件上应用涉及的成形特性问题。方法通过微观组织分析、单向拉伸、成形极限、V形弯曲回弹等试验,分析探讨了QP钢的力学性能、成形性能、成形极限和弯曲特性,并与广泛应用的DP钢对比。结果 QP钢HC600/980QP的成形性能好于相同强度级别的DP钢HC550/980DP,与HC420/780DP相当;QP钢弯曲回弹量比同等强度级别DP钢大。通过2个试冲零件的分析,验证了QP的成形特性,并从零件应用角度提出了QP钢的零件适用范围和零件设计要点。结论 QP钢具有综合的强度和塑性性能,有助于解决局部特征复杂的难成形零件和具有等截面特征的零件,在汽车车身结构件上有较大的应用前景。     

980 MPa先进高强钢材料在门槛加强梁上的辊压应用

目的为获得980 MPa级别不同先进高强钢材料在辊压零件上应用时的差异,研究典型980 MPa先进高强钢的辊压成形特性。方法采用调研和统计方法获得门槛辊压用材的主流强度与钢种,基于三点弯曲的实验方法,获得了980 MPa先进高强钢材料在指定角度和弯曲半径下的回弹特性,针对典型的门槛加强梁零件,采用CAE方法评估材料应用的可行性。结果门槛零件980 MPa级别所采用的主要先进刚强钢钢种为双相钢(DP)和马氏体钢(MS),在相对弯曲半径比R/t=2.5的情况下,980DP回弹角度最小,980QP次之,980MS最大;早期模具回弹补偿设计时对于90°圆角可给予11°~14°的回弹过弯角度;成形过程中有可能出现边波缺陷,需优化辊压成形变形过程。结论 980 MPa先进高强钢材料在应用于辊压零件时,应在设计阶段充分考虑材料回弹特性,同时变形过程应合理,避免产生边波等质量缺陷。     

高强钢帽形梁零件冲压减薄预测分析

目的 针对高强钢帽形梁强度高、塑性差、结构复杂、冲压过程中出现减薄破裂等情况,建立QP980高强度钢冲压成形减薄预测模型,解决实际生产工程难题。方法 以典型高强钢车身零件帽形梁为对象,利用人工神经网络模型研究工件结构和减薄率之间的关系,将贝叶斯优化算法和循环人工神经网络相结合,建立冲压成形减薄的高精度预测模型,对高强钢帽形梁零件冲压成形时减薄量进行优化设计,通过AutoForm软件验证算法模型的准确性。结果 拉深高度对减薄率影响最大,对外减薄率影响达到41.7%,对内减薄影响达到46.2%,人工神经网络模型对测试集5组数据的预测平均误差均小于0.3%。根据人工神经网络求解QP980钢在极限减薄率25%下的最大拉深高度为55.417 mm,人工神经网络预测结果与Autoform仿真结果相差0.3%,验证了人工神经网络模型的准确性。结论 采用该模型解决了CAE模拟在较少试验数据条件下算法预测精度差的问题,能有效缩短高强钢零件冲压成形调试周期,提高生产效率。     

先进高强度钢板弯曲类回弹特性的试验研究

随着先进高强钢板在汽车及航天航空领域的广泛应用,回弹导致的成形精度问题日益突出.为了获取先进高强钢的弯曲回弹特性,通过采用U形件回弹模型,针对600MPa级别的3种典型高强钢(DP钢、TRIP钢、HSLA钢)进行了回弹试验研究.实验结果表明:在相同变形条件下,TRIP钢弯曲回弹最大,DP钢次之,HSLA的弯曲回弹最小;不同工艺条件、不同材料性能参数对弯曲回弹呈单调的影响规律,而润滑条件对弯曲回弹的影响趋势并未出现一致性规律.     

车身用高强钢的回弹实验与分析

目的研究和分析身用高强钢在冲压过程中的回弹行为与规律。方法基于Wagoner的拉延弯曲实验模型,采用拉延弯曲(Draw-Bend)实验机,针对590 MPa级冷轧双相钢和420 MPa级低合金高强钢两个常用的典型车身用高强钢材料开展回弹实验研究,通过不同弯曲半径模拟不同冲压模具圆角半径,同时以不同张紧力模拟冲压压边力,讨论了两种材料的冲压成形及回弹性能与控制。结果两类钢的回弹量均随着冲压模具圆角半径的增大而减小,随着压边力的增大而减小,双相钢相比低合金能产生更大的回弹,厚板随冲压条件变化的回弹波动一般低于薄板。结论实验研究结果对高强钢在实际冲压过程中的回弹控制有着较强的指导意义。     

基于弯曲实验的DP980力学性能研究

目的 针对仅通过单向拉伸实验无法准确表征金属板材在弯曲成形过程中的力学性能变化的问题,研究通过弯曲实验获取材料力学性能参数.方法 对高强钢DP980展开力学性能测试研究,主要通过弯曲实验对材料弯曲变形过程中形成的弯矩曲率进行测试,将得到的弯矩曲率转化为应力-应变.分别将弯曲和拉伸得到的应力-应变数据导入到三点弯和辊弯成形有限元仿真中,预测板材的成形角度.结果 DP980弯曲变形时的屈服强度要大于轴向拉伸时的屈服强度;分别利用弯曲和拉伸实验测得的应力-应变数据进行仿真,与三点弯实验结果对比发现,采用弯曲实验得到的应力-应变数据对回弹量的预测偏大,而利用拉伸实验得到的应力-应变数据进行仿真,仿真得到的回弹量则偏小,弯曲实验下变形过程中的应变变化数据更加符合真实过程,与辊弯实验对比发现,利用弯曲实验数据进行仿真可以更准确地预测V形板的最终成形角度.结论 相较于单向拉伸实验,通过弯曲实验获取的材料力学性能参数可以更准确地描述材料在三点弯、辊弯成形过程中的力学性能变化.     

金属板材渐进成形工具头运动策略与成形质量分析

目的 研究渐进成形不同工具头运动策略对零件质量的影响,获取最佳运动策略,从而提高渐进成形零件的成形质量。方法 选取3种典型的渐进成形工具头运动策略与改进的运动策略进行有限元仿真,比较成形后的零件质量。结果 采用不同的运动策略均出现侧壁回弹、底部鼓包和厚度减薄缺陷,其中定间隔-下压点分散层切法轨迹成形后的零件缺陷最严重,侧壁最大回弹量和底部鼓包最大高度分别为11.5mm和3.9 mm,采用定间隔-交替运动层切法成形后的零件厚度减薄最严重,达到75.3%。改进的定弦长层切法轨迹成形件侧壁最大回弹量为9.2 mm,底部鼓包最大高度为2.7 mm,厚度减薄率为70.7%。结论 提出的定弦长层切法轨迹的成形策略能够有效避免零件底部出现压痕缺陷,获得的零件具有最好的形状精度和最小的厚度减薄率,相较于定增量-同方向进给轨迹成形,其侧壁最大偏差减小了14.8%,底部最大偏差减小了30.8%,相较于定轴向增量-交替进给轨迹成形,其厚度减薄减小了4.6%。     

先进高强度双相钢弯扭复合回弹评价与试验研究

目的 针对先进高强度双相钢冲压成形后回弹量大且多种回弹形式相互作用的问题,提出弯曲–扭曲复合回弹试验评价指标与测试方法,研究双相钢强度级别和试验条件对弯扭回弹的影响规律。方法 建立板料回弹前后的几何关系,提出弯扭复合回弹评价指标,通过改变三点弯曲试验上压杆的偏转角度,开展弯扭复合回弹试验。结果 基于合理的几何关系假设提出的评价指标适用于弯扭复合回弹试验结果分析。当上压杆偏转角度为0°时,强度越高,板料弯曲回弹越明显,回弹后横截面顶点距离和2条对角线长度变化越小;随着上压杆偏转角度的增加,当上压杆偏转0°～15°时,不同强度的3种试件（DP600、DP780、DP980）的横截面顶点距离和2条对角线长度增大,其中DP600试件的横截面顶点距离变化最小;当上压杆偏转15°～45°时,3种试件共同表现出横截面顶点距离减小、一条对角线长度减小、另一条对角线长度增加,其中DP980试件的对角线长度之差最小。结论 试验数据与分析结果表明,调整三点弯曲试验中上压杆的偏转角度可以诱发不同的扭曲回弹量,进而有效控制弯曲回弹与扭曲回弹的复合程度。分别利用板料横截面顶点距离变化及2条对角线长度变化评价弯曲回...     

高精度超高强钢长滑轨辊压制造技术

目的解决超高强钢辊压成形过程中回弹大、尺寸精度差、材料利用率低、生产效率低等问题,生产出高精度的超高强钢长滑轨产品,以满足市场需求。方法从截面形状、尺寸精度及冲孔要求三方面,对以DP980超高强钢材料成形的典型的滑轨产品进行了技术分析,针对该产品特性重点设计了冲孔方案,采用三步质量控制法对产品的成形过程及辊压模具设计进行了优化,最后采取多种方法对产品质量进行了全面检测。结果实际制造完成后的产品检测表明,通过优化模具设计及调整现场工艺,最终生产出的长滑轨各项指标均满足图纸要求,解决了超高强钢材料的成形难题。结论在超高强钢材料及尺寸较长产品的成形制造中,辊压成形技术相比其他成形工艺更加具有优势。     

平面应变板料拉弯成形回弹理论分析

基于平面应变假设,采用服从Hill平方屈服准则和指数强化材料模型,建立了板料拉弯成形回弹量预测的理论模型。应用该模型计算了一个拉弯成形回弹实例,分析了单位宽度切向拉力、凸模圆角半径、摩擦因数及各向异性参数对板料回弹量的影响。分析结果表明,只有当中性层偏移距离超过板厚的四分之一时,增大切向拉力才能有效地控制板料回弹量,而且弯曲半径越大,增大切向拉力控制板料的回弹量越为有效,然而拉力不能无限制的增大,它的计算准则为板料最外层的等效应变应不大于极限应变。同时还表明,摩擦因数对板料回弹量的影响随切向拉力的增大变得更为显著,而各向异性参数对板料拉弯成形回弹量的影响也较为明显。与有限元数值模拟预测结果的对比表明,理论模型预测板料拉弯成形回弹量与有限元数值模拟结果很接近。     

Evolution of elastic modulus in roll forming

Roll forming is a continuous process in which a flat strip is incrementally bent to a desired profile. This process is increasingly used in automotive industry to form High Strength Steel (HSS) and Advanced High Strength Steel (AHSS) for structural components. Because of the large variety of applications of roll forming in the industry, Finite Element Analysis (FEA) is increasingly employed for roll forming process design. Formability and springback are two major concerns in the roll forming AHSS materials. Previous studies have shown that the elastic modulus (Young’s modulus) of AHSS materials can change when the material undergoes plastic deformation and the main goal of this study is to investigate the effect of a change in elastic modulus during forming on springback in roll forming. FEA has been applied for the roll forming simulation of a V-section using material data determined by experimental loading-unloading tests performed on mild, XF400, and DP780 steel. The results show that the reduction of the elastic modulus with pre-strain significantly influences springback in the roll forming of high strength steel while its effect is less when a softer steel is formed.     

Effect of slide motion on springback in 2-D draw bending for AHSS

The springback behavior of two advanced high strength steel (AHSS) grades, DP 780 and DP 980, after different forming conditions, was investigated. 2-D draw bending experiments were performed using a direct-drive digital servo-press in three operation modes, conventional (V-mode), relaxation mode (Stepwise and U-mode) and the attach-detach (A-D mode). Numerical simulations were conducted to in an attempt to reproduce the results and to perform parametric studies. The material behavior was captured using the homogeneous anisotropic hardening (HAH) distortional plasticity approach together with the chord elastic modulus model. In addition, the stress relaxation effects were implemented in the code by using a creep law in order to study the influence of a stepwise slide motion mode as well as holding at the bottom dead center. Both experimental and finite element (FE) simulation results demonstrate that detachment of tools from the work-piece was effective to reduce the springback while the effect of stress relaxation was insignificant. The numerical analysis was validated and successfully explained the importance of a forming path change on the final stress state. Based on the result of this study, a new method to reduce springback was introduced.     

QP980高强钢制造的汽车地板纵梁拉延件的回弹分析

目的研究采用超高强钢QP980牌号的典型汽车梁类件在使用拉延工艺时的回弹特点,分析零件结构对实际回弹的影响过程与特点。方法先通过理论与仿真分析预测回弹,然后使用补偿后的模面开模进行试制,并搜集实际回弹数据,进行分析与对比。结果仿真分析可以准确预测零件一侧法兰的回弹,但对于另一侧法兰的预测精度相对较差。结论零件弯曲内侧侧壁存在局部剧烈弧形回弹是两侧法兰回弹存在差异的主要原因,而拉延序触料时与凹模圆角接触的材料部位对应弧形最大的位置,合模过程中凹模圆角与材料接触会导致料片的弧形弯曲,这种弯曲尤其在x向存在压应力的侧壁位置回弹显著,从而导致对应位置的法兰回弹尺寸超标。     

Springback prediction and reduction in deep drawing under influence of unloading modulus degradation

Springback is considered as one of the major problems in deep drawing of high-strength steels (HSS) and advanced high-strength steels (AHSS) which occurs during the unloading of part from the tools. With an ever increasing demand on the automotive manufactures for the production of lightweight automobile structures and increased crash performance, the use of HSS and AHSS is becoming extensive. For the accurate prediction of springback, unloading behavior of dual phase steels DP600, DP1000 and cold rolled steel DC04 for the deep drawing process is investigated and a strategy for the reduction of springback based on variable blankholder force is also presented. Cyclic tension compression tests and LS-Opt software are used for the identification of material parameters for Yoshida-Uemori (YU) model. Degradation of the Young’s modulus is found to be 28 and 26 and 14 % from the initial Young’s modulus for DP600, DP1000 and for the DC04 respectively for the saturated value. A finite element model is generated in LS-DYNA based on the kinematic hardening material model, namely Yoshida-Uemori (YU) model. The validation of numerical simulations is also carried out by the real deep drawing experiments. The springback could be predicted with the maximum deviation of 1.1 mm for these materials. For DP1000, the maximum springback is reduced by 24.5 %, for DP600 33.3 and 48.7 % for DC04 by the application of monotonic blankholder force instead of a constant blankholder force of 80 kN. It is concluded that despite the reduction of Young’s modulus, the springback can be reduced for these materials by increasing the blankholder force only in last 13 % of the punch travel.     

Analysis of stamping performances of dual phase steels: A multi-objective approach to reduce springback and thinning failure

The industrial interest on light weight components has contributed in the last years to a significant research effort on new materials able to guarantee high mechanical properties, good formability and reasonable costs together with reduced weights when compared to traditional mild steels. Among such materials advanced high strength steels (AHSS) such as transformations induced plasticity (TRIP) and dual phase (DP), and light weight alloys proved their usefulness in stamping of automotive components. As AHSS are concerned, one of the main drawbacks is related to springback occurrence. Many aspects have to be taken into account when springback reduction is investigated: material behavior issues, process conditions, numerical simulations parameters calibration, geometrical aspects and so on. Moreover, springback minimization problems are typically multi-objective ones because springback reduction may conflict with other goals in stamping design such as thinning reduction. In this paper, such problem was investigated through integration between numerical simulations, Response Surface Methodology and Pareto optimal solutions search techniques. The design of a U-channel stamping operation was investigated utilizing two different dual phase steel grades: DP 1000 and DP 600. An explicit/forming-implicit/springback approach was utilized for the numerical simulations. Friction conditions and blank holder force were optimized as design variables in order to accomplish two different objectives: reduce excessive thinning and avoid excessive geometrical distortions due to springback occurrence.