不锈钢钢板热应力成形试验研究及其工艺参数评价

以不锈钢钢板为研究对象,通过改变激光光束能量、光斑直径、机床扫描速度、扫描次数以及扫描路径对不锈钢钢板进行弯曲试验,研究了厚度一定的不锈钢钢板弯曲成形时的工艺参数对弯曲角度的影响,并对热应力弯曲成形的工艺参数进行评估。     

工艺参数对管材激光弯曲成形影响规律的研究

管材激光弯曲成形是一种柔性金属塑性成形方法。将连续的激光光斑简化为一间歇跳跃的方形匀强面热源,并考虑材料性能参数与温度的相关性,建立了管材激光弯曲成形的热-机耦合有限元工艺仿真模型,对成形过程进行了数值模拟。有限元模拟结果表明:在其他条件不变的情况下,激光弯曲角度随激光功率的增大而增大,两者基本上成线性关系;弯曲角度随扫描速度的升高而减小,随光斑直径的减小而增大,但当光斑直径减小到一定程度后,弯曲角度开始减小;弯曲角度随扫描包角的增大而增大,当扫描包角为180°时,弯曲角度达到最大,弯曲角度随扫描包角的继续增大而减小;扫描次数与弯曲角度间成近似的线性关系,且第一次扫描管材产生的弯曲角度最大。     

金属薄板激光弯曲成形的工艺参数研究

以不锈钢薄板的激光弯曲成形为研究对象,研究其成形的工艺过程及影响因素;介绍实验设备和激光调焦方法。通过实验研究了激光能量因素、扫描速度因素、激光光斑大小和扫描次数等因素对弯曲成形角度的影响。     

不锈钢薄板的激光弯曲成形试验研究

以不锈钢薄板的激光弯曲成形为研究对象，通过实验研究其成形过程及影响因素。首先介绍了激光成形的工艺过程及影响因素；然后通过试验研究了激光能量、扫描速度、激光光斑大小和扫描次数等因素对弯曲成形角度的影响。     

金属层合板激光圆弧扫描弯曲成形试验研究

采用激光圆弧扫描弯曲策略,针对矩形层合板主要分析激光功率P、离焦量H、激光扫描速度v以及层合板厚度h对层合板弯曲角度及曲面变形量的变化规律及其影响作用。研究结果表明:激光功率P增大,层合板弯曲角度及曲面变形量随之增大;离焦量H、激光扫描速度v以及层合板厚度h增大,层合板弯曲角度及曲面变形量随之减小;通过激光圆弧扫描弯曲,层合板呈显著三维曲面特征,激光圆弧扫描弯曲成形时层合板长度方向中线处弯曲角度小于层合板两侧边线弯曲角度,且激光扫描线处曲面变形量最大。基于矩形层合板曲面变形特征,为实现圆顶形激光弯曲三维曲面成形,最终利用圆形层合板,采用激光径向+轴向扫描策略弯曲成形圆顶形结构,其最外侧圆周测量线z向最大位移增量达到2. 23 mm。     

基于吸收系数修正的硅片激光弯曲模拟与实验

考虑热吸收系数随温度变化的因素,以硅为对象进行了激光弯曲模拟和实验。借助APDL语言编写了激光弯曲成形的仿真程序,对单脉冲作用过程进行模拟,以得到单点脉冲周期内的温度分布;采用NiCr／NiSi合金薄膜热电偶对单脉冲作用过程中的温度分布进行测量,对比上述的温度模拟与测量结果,修正硅材料的激光综合吸收系数为0．82。采用有限元分析软件实现了硅片的脉冲激光弯曲成形的仿真和模拟,并对硅片多次连续扫描的弯曲模拟与弯曲实验进行对比,误差仅为0．1°,验证了仿真程序的有效性,为硅片的激光弯曲成形提供了理论与实验依据。     

硅片的激光吸收系数修正与弯曲试验

考虑热物性能参数随温度变化的因素,以硅为对象进行激光弯曲模拟和试验,借助APDL语言编写激光弯曲成形的仿真程序,对单脉冲作用过程进行模拟,以得到单点脉冲周期内的温度分布;并采用NiCr/NiSi合金薄膜热电偶对单脉冲作用过程中的温度分布进行测量,对比上述的温度模拟与测量结果,修正硅材料的激光综合吸收系数。采用有限元分析软件实现了硅片的脉冲激光弯曲成形的仿真和模拟,并对多次连续扫描的模拟结果与硅片弯曲试验结果进行对比,验证了仿真程序的有效性,为硅片的激光弯曲成形提供了理论与试验依据。     

1Cr13不锈钢板激光弯曲数值模拟

在综合分析了材料的热物理性能和力学性能随温度变化影响的基础上,建立了板料激光弯曲成形的三维热力耦合模型.对1Cr13不锈钢钢板的激光单次扫描弯曲过程进行了数值模拟,得到了形变场、温度场以及应力场模拟结果,并对其变形过程和变形机理进行了分析.     

等离子电弧加热弯曲精确成形试验

为了实现等离子电弧加热的精确弯曲成形,采用等离子电弧沿直线对1Cr18Ni9Ti不锈钢板材进行加热弯曲成形试验,并用CMOS1303uc数字相机等硬件和相关软件在等离子电弧加热弯曲成形的过程中对弯曲角度进行实时检测,实现了对成形过程的闭环控制。试验结果表明:当扫描次数较少时,板材弯曲角度随扫描次数增加近似呈线性增大;当扫描次数较多时,由于增厚效应的影响,单次扫描弯曲角度的增量会不断减小,弯曲效率明显降低。为了确保加工过程的可靠性并提高成形效率,根据加工余量的不同将成形过程分为粗、中、精三个加工阶段,各个阶段分别采用不同的工艺参数进行加工,通过弯曲角度分别为20°和30°的不锈钢薄板的成形试验验证了该方法的有效性。     

管材激光弯曲成形的试验研究

进行了管材激光弯曲的试验研究,确定了工艺参数范围及扫描方式。通过单因素试验法研究了不同的激光参数(激光功率、扫描速度、离焦量和扫描包角)、扫描次数和管径对弯曲角度的影响规律,从而得到了单因素条件下的最佳工艺参数,为激光弯曲成形零件提供了应用基础。     

超薄镀锌板辊弯成形回弹工艺分析

对于超薄镀锌板,厚度薄回弹量大难以控制是运用辊弯成形方法中的难点之一。基于ABAQUS有限元软件建立了超薄板辊弯成形仿真模型,以单波模型为例,运用正交试验方法分析了压型板的回弹,详细分析了相对弯曲半径变化对回弹的影响。研究表明,材料厚度增加、弯角半径减小时,回弹角度会减小;在一定范围内较少道次数也能减小回弹角度;板材回弹角度与r／t值成线性关系。     

Process simulation and optimization of laser tube bending

A 3D thermomechanical finite element analysis model for laser tube bending is developed based on the software MSC/Marc. The processes of single- and multi-scan are analyzed numerically. The gradient and development of the temperature between the laser scanning side and the nonscanning side leads to the changing complexity of the stress and strain. Consequently, the length of the laser scanning side becomes shorter than that of nonscanning side after cooling. The length difference between both sides makes the tube produce the bending angle. The relationship between the number of scans and the bending angle is about in direct ratio. The bending angle induced by the first irradiated time is largest. Meanwhile, the finite element simulation is integrated with the genetic algorithm. Aiming at different process demands, corresponding objective functions are established. Laser power, beam diameter, scanning velocity, and scanning wrap angle are regarded as design variables. Process optimizations of maximum angle bending and fixed angle bending after single laser scan are realized. Groups of optimized process parameters can be obtained according to different optimization objectives. The bending angle can approach to the maximum when the laser power, spot diameter, scanning velocity, and scanning wrap angle are 381.24 W, 3.37 mm, 16.34 mm/s, and 123.1°, respectively. When the laser power, spot diameter and scanning velocity are 426.12 W, 4.9 mm, 14.31 mm/s respectively, a fixed angle bending can be achieved.     

CO2连续激光弯曲硼硅酸盐玻璃薄片实验研究

利用CO2连续激光对硼硅酸盐玻璃薄片进行了弯曲试验,研究了激光功率（P）、扫描速度（V）、扫描次数（n）及样品宽度（d）对弯曲效果的影响,并简要分析了弯曲现象产生的原因。给出了弯曲加工的P,V范围图,获得多组可以成功弯曲玻璃样品的工艺参数。实验结果表明,采用CO2连续激光可以对硼硅酸盐玻璃薄片进行弯曲加工,弯曲角度可达24°以上。     

Experimental analysis of sheet metal micro-bending using a nanosecond-pulsed laser

Laser shock bending is a sheet metal micro-forming process using shock waves induced by a nanosecond-pulsed laser. It is developed to accurately bend, shape, precision align, or repair micro-components with bending angles less than 10°. Negative bending angle (away from laser beam) can be achieved with the high-energy pulsed laser, despite the conventional positive laser bending mechanism. In this research, various experimental and numerical studies on aluminum sheets are conducted to investigate the different deformation mechanism, positive or negative. The experiments are conducted with the sheet thickness varying from 0.25 to 1.75 mm and laser pulse energy of 0.2 to 0.5 J. A critical thickness threshold of 0.7-0.88 mm is found that the transition of positive–negative bending mechanism occurs. A statistic regression analysis is developed to determine the bending angle as a function of laser process parameters for positive bending cases.     

Springback prediction of the vee bending process for high-strength steel sheets

The precise prediction of springback is a key to assessing the accuracy of part geometry in sheet bending. A simplified approach is developed by considering the thickness ratio, normal anisotropy, and the strain-hardening exponent to estimate the springback of vee bending based on elementary bending theory. Accordingly, a series of experiments is performed to verify the numerical simulation. The calculation of the springback angle agrees well with the experiment, which reflects the reliability of the proposed model. The effects of process parameters such as punch radius, material strength, and sheet thickness on the springback angle are experimentally tested to determine the dominant parameters for reducing the springback angle in the sheet bending process for high-strength steel sheets. Moreover, the effects of the thickness ratio, normal anisotropy, and the strain-hardening exponent on the springback angle in the vee bending process for high-strength steel sheets are theoretically studied. Therefore, improving understanding on and control of the springback reduction of the vee bending process in practical applications is possible.     

An experimental investigation on passive water cooling in laser forming process

The effect of passive water cooling in laser forming of thin sheets made of AISI 304 stainless steel is experimentally investigated. Indeed, since each laser scan can produce only small bending angles, multiple laser scans are required to produce a given deformation with a significant increase of production time due to cooling between consecutive scans. Therefore, passive water cooling is tested to verify its influence on minimum time between consecutive scans (cooling time), bending angle, and surface quality. A parametric approach is involved in the investigation and main process parameters are changed among the experiments by varying laser scanning speed, laser beam power, sheet thickness, and cooling media among several levels. It was discovered that the employment of passive water cooling in laser forming of thin sheets would be beneficial since the capability to dramatically reduce the cooling time and oxidation of both irradiated and cooled surfaces. In addition, the bending angle is only marginally affected by employment of water cooling. The effect of water cooling on stress and deformations are discussed by developing a numerical model based on finite element model.     

硅片激光弯曲成形的数值模拟与实验

介绍了一种利用脉冲激光塑性化弯曲单晶硅片的新方法。在分析和描述光脉冲时空特性的基础上,运用有限元分析软件ANSYS对硅片弯曲过程进行建模仿真,得到了脉冲激光弯曲过程中温度场与应力应变的仿真结果。对脉冲激光作用过程中温度场与应力应变的周期性瞬间变化特征进行了描述,指出了脆性材料硅片的脉冲激光弯曲机理不属于简单意义上的温度梯度机理或屈曲机理,而是二种机理共同作用的结果。通过6次扫描试验实现了对硅片的有效弯曲,弯曲角度达6.5º,仿真结果与验证性试验相符。