一种确定管材本构参数的新方法及其应用

管材力学性能参数是研究管材数控弯曲变形行为的关键因素之一.采用将人工神经网络、有限元模拟以及基于平面应力状态的拉伸实验相结合的参数识别方法,获得了尺寸因子(D/t)为50的铝合金管(5052O)的塑性本构参数.同时,基于ABAQUS软件平台,建立了数控弯管三维弹塑性有限元模型,并利用该模型研究了不同本构参数对弯管塑性变形行为的影响.结果表明:与传统单向拉伸测试相比,采用本文方法获得的管材塑性本构参数模拟的管材外弧面塑性变形行为与实验结果更接近.     

高强钢TRB高温下热流变特性

为了准确仿真高强钢板热冲压成形过程,获得高强钢高温下的材料本构关系模型,利用Gleeble3500热模拟试验机在不同温度和应变速率下对不同厚度的高强钢B1500HS钢板进行了单向拉伸试验,获得各种工艺条件下的应力-应变曲线,并基于变形抗力数学模型,引入板材厚度参数,通过最小二乘法进行数据拟合获得高强钢TRB高温下的材料本构关系.利用试验结果对本构关系模型进行的拟合验证表明,拟合程度较好,说明建立的材料本构关系能很好地描述高强钢TRB在高温下的应力-应变关系.     

基于Hoek-Brown准则的应变软化模型有限元数值实现研究

研究提出一种Hoek-Brown（H-B）准则应变软化模型的有限元数值实现方法。分析当前不同脆塑性计算方法的合理性,发现塑性位势跌落可正确计算岩石不同类型破坏,而偏应力等比例跌落和最小主应力不变跌落均存在不足。在此基础上,推导写出基于塑性位势跌落的H-B准则脆塑性隐式本构积分算法,及H-B准则理想弹塑性隐式本构积分算法,并采用一系列应力跌落-塑性流动,将H-B准则应变软化模型嵌入有限元软件ABAQUS中。比较应变软化圆隧围岩收敛位移及应力分布的解析解与本文有限元解,发现二者吻合良好,验证了所建H-B准则应变软化模型的正确性。对某薄上覆盖岩层高内水压输水隧洞工程的计算结果表明,相较理想弹塑性模型,所建应变软化模型可正确反映隧洞顶部围岩塑性区贯通引起的整体结构失稳破坏现象,为工程选择衬砌方案提供依据。     

砂土统一本构模型研究及其三维数值实现

基于广义塑性理论与临界状态概念,研究提出了一个统一三维砂土本构模型,通过一组参数实现了砂土由压缩至剪切过程中状态参量的统一表述。基于ABAQUS提供的用户自定义材料子程序UMAT接口,利用Fortran语言编程实现了该三维弹塑性本构关系模型在软件中的二次开发。分别利用Toyoura砂、Fuji River砂以及Tokachi砂的剪切试验数据与数值模拟结果进行对比,结果表明:提出的有限元计算模型可以有效反映加载过程中不同围压和砂土初始密度对应力-应变曲线的影响,能够准确描述密砂的剪胀特性与应变软化特性以及松砂的剪缩特性与应变硬化特性,从而更加真实地反映三维应力状态下土的变形和强度特性。研究成果进一步扩展了ABAQUS在岩土工程中的应用范围,能够为岩土工程领域的数值分析计算提供更加快捷的解决方案。     

弹塑性本构模型计算冻结壁应力场和位移场

应用冻结壁在卸载状态下冻结壁-周围土体共同作用的力学模型,基于大量的冻土应力-应变关系曲线的试验,采用弹塑性非线性本构模型计算冻结壁应力场和位移场.计算结果表明,由于冻结壁在周围土体共同作用下外载比原始水平应力要低,计算的应力场和位移场和有限元模拟接近地.     

应力三轴度和应变率对6063铝合金力学性能的影响及材料表征

对6063铝合金试样在不同应力三轴度和不同应变率下进行拉伸试验,得到了该合金在这两种情况下的力学性能.研究结果表明:随着应力三轴度的减小,材料的等效弹性模量、等效屈服应力减小,但等效断裂应变增大;随着应变率逐渐增大,材料的屈服强度和断裂强度略有增大;断裂应变明显减小;抗拉强度基本不变.Johnson-cook本构模型及其断裂应变模型可以用来描述6063铝合金在不同三轴应力度和不同应变率下的本构及失效关系.通过材料表征,得出了Johnson-cook本构模型及其断裂应变模型中各个参数,为有限元(ABAQUS)模拟提供帮助.     

基于不可逆热力学的Ni-Ti合金动态本构模型及其有限元实现

为了准确描述Ni-Ti形状记忆合金在高应变率下的动态压缩力学行为,基于不可逆热力学理论框架假定了两个内变量表征Ni-Ti合金应力诱发马氏体相变与塑性屈服的不可逆变形过程,分别推导了马氏体相变与塑性屈服演化规律的主控方程,构建了Ni-Ti合金的三维动态本构模型。根据材料单轴动态压缩实验的应力-应变曲线并采用最小二乘法对本构参数进行了优化识别,然后采用应力补偿更新算法,通过隐式用户子程序接口UMAT将动态本构模型嵌入ABAQUS有限元软件,实现了Ni-Ti合金在高应变率下动态压缩力学行为的数值模拟。通过比对发现,模拟结果与实验数据吻合良好,验证了动态本构模型与UMAT子程序的准确性。本工作为Ni-Ti合金在高速冲击、切削等极端条件下的工程应用奠定了基础。     

基于金属板材渐进折弯成形的闭环控制系统性能分析

为了解决板材成形回弹问题,将自动控制理论中反馈控制的思想引入到板材渐进折弯成形过程.利用先进的控制技术来解决板材工件的精确成形.然而,闭环控制的稳定性、准确性和快速性会直接影响到系统的正常工作.针对闭环系统稳定性对工件成形品质的影响,建立了渐进折弯成形闭环控制系统模型.通过理论推导,利用小线性化处理及模型简化方法求解闭环系统传递函数及特征方程.采用离散根轨迹法并进行了Matlab/Simulink仿真试验,其结果表明,系统总增益等于一时能确保成形工件形状稳定、快速、准确收敛到目标形状.     

复合材料非线性本构关系的机算机模拟

本文对单向连续纤维增强复合材料的弹塑性本构关系进行了数值模拟。首先提出了基于统一弹粘塑性本构理论的有限无法,然后利用微观力学模型研究了弹性纤维增强弹粘塑性基体的复合材料应力——应变关系。     

半固态流变行为模型及应用

半固态成形是21世纪最具潜力的先进制造技术之一.分析了国内外半固态变形行为研究进展,重点阐述了近似单相本构关系模型、两相本构关系模型、宏观-微观耦合本构关系模型的特点及应用,特别是笔者提出的宏观-微观耦合本构关系模型反映了工艺参数和微观组织参数对半固态流变应力的影响.同时,笔者将新型宏观-微观耦合本构关系模型应用于Al-4Cu-Mg合金半固态反挤压过程的有限元数值模拟,获得了工艺参数对应力应变、温度、晶粒尺寸、液相体分数和挤压载荷等的影响规律,数值模拟结果与半固态实验结果基本一致.     

Using genetic algorithm-back propagation neural network prediction and finite-element model simulation to optimize the process of multiple-step incremental air-bending forming of sheet metal

Using neural network to predict punch radius based on the results of air-bending experiments of sheet metal is a high efficiency work in spite of little error. A three-layer back propagation neural network (BPNN) is developed to best fit this discrete engineering problem involving many parameters of air-bending forming. A genetic algorithm (GA) is used to optimize the weights of neural network for minimizing the error between the predictive punch radius and the experimental one. Then, with the predicted punch radius and other geometrical parameters of a tool, 2D and 3D ABAQUS finite-element models (FEM) are established, respectively. The original forming process of multiple-step incremental air-bending of sheet metal, obtained from geometric planning for semiellipse-shaped workpiece, is simulated using the FEM. This process is further adjusted with simulation-optimization results, because of existing large errors in the workpiece simulated with the original forming process. Finally, a semiellipse-shaped workpiece, with average errors of +0.61/−0.62 mm, is manufactured with the optimized adjustment process. The experimental results show that the punch design method is feasible with the prediction model of GA-BPNN, and the means of optimizing process with FEM simulation is effective. It can be taken as a new approach for punch and process design of multiple-step incremental air-bending forming of sheet metal.     

Evaluation of yield criteria for forming simulations based on residual stress measurement

Process induced anisotropy in sheet metal is accounted for in analytical modeling by anisotropic yield criteria. The suitability of a yield criterion for predicting sheet metal forming process is generally validated by way of its ability to predict surface strains. However, the sensitivity of surface strains to yield criteria is dependent upon strain modes, with plane strain mode exhibiting higher sensitivity. To eliminate dependency on strain modes, stresses are used to evaluate yield criteria, since forming stresses are less sensitive to strain modes. In the study, the residual stresses remaining in a hemispherical cup formed in plain strain mode is predicted using Hill48 and Barlat89 criteria. The residual stresses are experimentally characterized by using X-Ray diffraction method. Suitable yield criterion for forming simulation is validated based on the correlation of theoretical predictions with experimental residual stress values.     

利用最小厚度准则预测高强热轧钢板的FLC曲线

为更便捷地获得成形极限图(FLD)中的成形极限曲线(FLC),用最小厚度准则,通过少量成形极限试验结合数值模拟来预测FLC.采用Barlat1989屈服准则对QStE340TM、SAPH370、ZStE260P三种高强度热轧钢板进行成形极限模拟,并以最小厚度准则作为极限判据,根据数值模拟结果绘制FLC图.计算结果表明,采用平面应变路径下的成形极限实验数据作为最小厚度准则的已知参数时,数值预测结果与实验结果能较好吻合.故采用平面应变路径下的成形极限实验数据,结合最小厚度准则和数值模拟,即可得到材料完整的FLC曲线.     

Plane strain transversely anisotropic analysis in sheet metal forming simulation using 6-component Barlat yield function

In most FEM codes, the isotropic-elastic and transversely anisotropic-elastoplastic model using Hill??s yield function has been widely adopted in 3D shell elements (modified to meet the plane stress condition) and 3D solid elements. However, when the 4-node quadrilateral plane strain or axisymmetric element is used for 2D sheet metal forming simulation, the above transversely anisotropic Hill model is not available in some FEM code like Ls-Dyna. A novel approach for explicit analysis of transversely anisotropic 2D sheet metal forming using 6-component Barlat yield function is elaborated in detail in this paper, the related formula between the material anisotropic coefficients in Barlat yield function and the Lankford parameters are derived directly. Numerical 2D results obtained from the novel approach fit well with the 3D solution.     

Effect of continuous strain path changes on forming limit strains of DP600

The strain path may change in actual sheet metal‐forming processes, so the determination of formability of sheet metal should consider the nonlinear strain path. For identifying the forming limit (FL) strains under nonlinear strain path, a conventional two‐step procedure with unloading is classically used to produce the strain path change, which results in no continuous measure of strain. The in‐plane biaxial tensile test with a cruciform specimen is an interesting alternative to overcome the drawbacks of conventional method. The strain path change can be made without unloading during a single test. In this work, the experimental FL strains of DP600 sheets under two types of nonlinear strain path are investigated and then compared with those under linear strain paths. The Oyane ductile fracture criterion is used in the finite element simulation to predict the experimental results.     

大尺度U形板材工件鼓形翘曲缺陷分析及消除

为研究折弯成形工件翘曲的形成机理,提出了一种采用实验、数值模拟和理论分析相结合方法.以一大尺度半椭圆形工件成形为例,对该工件渐进折弯中非均匀回弹翘曲全过程进行ABAQUS有限元数值模拟.分析指出大折弯力、折弯机床身变形是工件鼓形翘曲的主要原因.实施了采用凹模大开口、折弯机床身变形反向挠度补偿的工件缺陷消除措施.工程应用结果表明,该方法对提高工件的成形精度及消除工件翘曲变形缺陷等均获得满意的效果.     

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。     

Approximate yield criteria for anisotropic porous ductile sheet metals

An approximate macroscopic yield criterion for anisotropic porous sheet metals is developed under plane stress conditions in this paper. The metal matrices are assumed to be rigid perfectly plastic and incompressible. The Hill quadratic and non-quadratic anisotropic yield criteria are used to describe the matrix normal anisotropy and planar isotropy. The voids in sheet metals are assumed in the form of through-thickness holes. Under axisymmetric loading, a closed-form upper bound macroscopic yield criterion is derived as a function of the anisotropy parameter R, defined as the ratio of the transverse plastic strain rate to the through-thickness plastic strain rate under in-plane uniaxial loading conditions. The plane stress upper bound solutions for different in-plane strain ratios can be fitted well by the closed-form macroscopic yield criterion.     

Investigation of anisotropy problems in sheet metal forming using finite element method

This paper discusses the results of the numerical study of rectangular cup drawing of steel sheets using finite element methods. To be able to verify the results of the numerical solutions, an experimental study was done where the material behavior under deformation was analyzed. A 3D parametric finite element (FE) model was built using the commercial FE-package ABAQUS/Standard. ABAQUS allows analyzing physical models of real processes putting special emphasis on geometrical non-linearities caused by large deformations, material non-linearities and complex friction conditions. Friction properties of the deep drawing quality steel sheet were determined by using the pin-on-disc tribometer. The results show that the friction coefficient depends on the measured angle from the rolling direction and corresponds to the surface topography. A quadratic Hill anisotropic yield criterion was compared with von Mises yield criterion having isotropic hardening. The sensitivity of constitutive laws to the initial data characterizing material behavior is also presented. It is found out that plastic anisotropy of the matrix in ductile sheet metal has influence on deformation behavior of the material. When the material and friction anisotropy are taken into account in the finite element analysis, this approach gives better approximate numerical results for real processes.     

屈服准则用于高强度热轧钢板的适用性分析

为确定适合描述高强度热轧钢板变形行为的屈服准则,采用Hollomon流动应力方程和三种屈服准则对几类高强度热轧钢板在不同应变路径下达到成形极限的成形过程进行了模拟.比较了Barlat(1989)、Hill(1948)、Barlat六参数3种屈服准则,对热轧酸洗板QStE340TM、SAPH370和热轧镀锌板ZStE260P在单向拉伸、平面应变和双向等拉3种应变路径下的变形过程进行了比较.结果表明,Barlat(1989)屈服准则能较好地描述单元的变形行为,且在平面应变路径下的模拟结果最符合实验结果.