板料成形有限元模拟中的拉格朗日分析方法

数值模拟中的模拟方法对于建立一个可信赖的有限元模型非常重要。板料成形中包含大变形、大位移和摩 擦行为,模拟结果对不同的有限元模型有很大的不确定性。采用有限元软件MARC基于不同拉格朗日法建立了一 个有限元模型来分析深冲压成形过程。模拟中板料作为变形体,模具看作刚体,接触面间的摩擦约束采用修正的库 仑摩擦模型。板料应变、厚度的模拟和实验结果比较表明完全拉格朗日法(T.L.)和更新拉格朗日法(U.L.)的主 要区别在大变形和大位移上,小变形和小位移两者吻合较好。     

考虑接触演变的板材回弹过程建模与优化

回弹是由工件在卸载后的弹性变形引起的。板料成形过程中为了控制成形件的最终形状,必须进行回弹设计优化。准确预测回弹对于板料成形过程的模具设计非常重要。降低回弹模拟结果与试验结果的偏差是设计过程中的难题。基于NUMISHEET’02的自由弯曲标准考题考虑板材与模具间的接触演变过程,建立了一个有限元模型来预测回弹。采用一个常规的优化方法对有限元分析中的材料和单元模型进行了分析,研究发现不同模型对回弹结果有较大影响。模拟结果与参考文献中的试验结果比较表明了模型的正确性和可行性。     

汽车横梁拉深成形的有限元分析

建立了汽车横梁拉深的有限元三维模型，对其拉深成形过程进行了数值模拟，并与实验结果对比分析，说明数值模拟方法的可行性。在此基础上讨论了摩擦润滑条件、压边力和凸模的虚拟冲压速度对板料拉深过程的影响。通过有限元模拟分析方法得到最佳压边力数值，然后通过综合分析数值模拟结果和拉深实验结果确定了实际拉深过程中的最佳压边力。结果表明，在实际拉深过程中要尽量减小模具和板料的摩擦；在模拟拉深成形时，当虚拟冲压速度大于一定值时，会使模拟结果严重失真，因此，汽车横梁拉深数值模拟时最大虚拟冲压速度不要大于2000mm／s。     

金属板材拉深过程的数值模拟研究

针对金属板料拉深过程中材料变形十分复杂的问题,建立了适合钢板拉深过程的三维有限元模型,采用所建立的有限元模型对板料拉深过程进行了数值模拟研究,研究了板料拉深过程中的变形情况,并对拉深过程中冲压力和金属板料的应力分布进行了分析。数值模拟结果与实际拉深过程中材料的变形过程一致,验证了三维有限元模型的正确性。     

确定拉延筋约束阻力的一种数值模拟方法

利用率形式的虚功原理和考虑弯曲影响的 Mindlin曲壳单元 ,根据塑性变形体积不可压缩的假设 ,将大变形弹塑性有限元应用于板料成形过程中 ,建立了接触摩擦模型。在此基础上 ,利用自行开发的软件 Sheet Form模拟板料流经拉延筋的过程 ,确定板料成形数值模拟中建立等效拉延筋模型需要的拉延筋约束阻力、塑性厚向应变和最小压边力 3个边界条件 ,并与Nine等人的实验结果进行对比 ,证明了该方法的有效性     

基于ANSYS/LS-DYNA的板料拉深数值模拟研究

基于连续介质力学及有限元理论,运用动力显式算法建立有限元模型,采用ANSYS/LS-DYNA软件模拟圆形板料的拉深过程,在三种不同加载路径下,研究圆形板料在拉深方向的最大应力和板料厚度的变化规律,以及不同加载方式对板料成形质量的影响,所得结果可为生产实际提供指导.     

有限元数值模拟技术在汽车冲压成形中的应用

介绍在板料成形中应用有限元数值模拟技术的优点,并利用有限元软件DYNAFORM对一个汽车覆盖件成形过程进行数值模拟。从计算结果分析对成形过程产生影响的一些因素。最后总结数值模拟技术对板料成形的重要性。     

板成形摩擦因数测量过程中影响因素分析

摩擦因数对有限元模拟结果的正确性有着很大的影响，通常使用的板料摩擦因数测试方法大都基于Ducan原理，在测试中摩擦圆辊直径和摩擦包角的大小对最终的测试结果有很大影响。设计了新的摩擦因数测试装置，考察圆辊直径和圆辊摩擦包角大小对摩擦因数计算的影响，并进行了理论分析。试验表明，随着圆辊直径和摩擦包角的增大，由弯曲和包角边界造成的干扰将逐级减小，从而计算摩擦因数也逐步减小，并且最终趋向真实摩擦因数。基于试验和有限元计算，得出包角大于90°、圆辊直径大于30mm时，测得的摩擦因数能较准确地反映当前的摩擦状况，可以用于板料成形模拟的结论。     

多工步橡皮成形工艺过程数值模拟研究

采用非线性有限元分析软件对复杂飞机舱门内衬板零件的橡皮成形过程进行计算机模拟。涉及到模拟算法的选择,多工步成形与回弹的数据处理技术,多个工步成形工艺设计,摩擦算法、罚参数的确定;预示和分析了3个工步的模拟过程中板料回弹,材料变薄,起皱,板料贴模的影响因素。     

金属板料冲压成形的数值模拟

本文采用有限元动力显式算法模拟金属板料冲压成形的加工过程。四结点蜕化壳单元和刚体壳单元分别用来建立权和模具的有限元模型;更新Ｌａｇｒａｎｇｅ法和速率型本构关系被用来处理板料变形中的大应变和大转动;材料模型采用塑性各向异性屈服与等向强化模型;通过主从面模型定义板料和模具的接触,接触算法采用运动约束法,摩擦力用库仓定律计算;并利用动力松弛法对回弹过程进行了计算。模拟结果和实际零件比较,证明模型合理,算法稳定,结果可靠,具有良好的应用价值。     

冲压模参数化NURBS曲面造型及有限元网格划分

针对冲压模具的特点 ,提出了模具型面参数化NURBS曲面分片 ,局部网格调整的思想 ,较好地解决了板料成形有限元模拟前处理中模具型面造型及网格划分的问题。基于NURBS方法 ,在VC + +平台上开发了一个NURBS曲面造型及网格生成系统 ,对实际的盒形件拉深凹模型面进行了描述 ,获得了满意的曲面形状 ;基于参数空间法对型面进行了四边形网格剖分 ,并自动实现四边形到三角形网格的转换     

Development of a hydroforming setup for deep drawing of square cups with variable blank holding force technique

Sheet hydroforming is a process that uses fluid pressure for deformation of a blank into a die cavity of desired shape. This process has high potential to manufacture complex auto body and other sheet metal parts. Successful production of parts using hydroforming mainly depends on design aspects of tooling as well as control of important process parameters such as closing force or blank holding force (BHF) and variation of fluid pressure with time. An experimental setup has been designed and developed for hydroforming of square cups from thin sheet materials. Square cups have been deep drawn using constant and variable BHF techniques. A methodology has been established to determine the variable BHF path for successful hydroforming of the cups with the assistance of programmable logic controller and data acquisition system. Finite element (FE) simulations have also been carried out to predict formability with both of these techniques. It has been found that it is possible to achieve better formability in terms of minimum corner radius and thinning in the case of variable BHF technique than in the case of constant BHF technique (constant force during forming and calibration). The results of FE analysis have been found to be in good agreement with experimental data.     

A study on high ratio cup drawing by Maslennikov’s process

Deep drawing of sheet metals using Maslennikov’s technique has been analyzed by analytical and finite element simulation approaches. A new friction model based on local contact conditions has been used in the finite element (FE) simulations of the process. Compared to traditional Coulomb friction model, the results of FE simulations with the new friction model show good correlation with analytical calculations. The effects of key process parameters such as rubber ring thickness, ring inner diameter, die hole diameter, and die profile radius on the results have been investigated. The results showed that very deep cups without thinning in the side wall portion can be achieved with this process. Based on the results of FE analysis, it was found that the maximum drawing ratio can be achieved by adopting a combination of process parameters which correspond to points nearest to the fracture limit.     

Investigations on the effects of friction modeling in finite element simulation of machining

Accurately predicting the physical cutting process variables, e.g. temperature, velocity, strain and stress fields, plays a pivotal role for predictive process engineering for machining processes. These predicted field variables, however, are highly influenced by workpiece constitutive material model (i.e. flow stress), thermo-mechanical properties and contact friction law at the tool-chip-workpiece interfaces. This paper aims to investigate effects of friction modeling at the tool-chip-workpiece interfaces on chip formation process in predicting forces, temperatures and other field variables such as normal stress and shear stress on the tool by using advanced finite element (FE) simulation techniques.For this purpose, two distinct FE models with Arbitrary Lagrangian Eulerian (ALE) fully coupled thermal-stress analyses are employed to study not only the effects of FE modeling with different ALE techniques but also to investigate the influence of limiting shear stress at the tool-chip contact on frictional conditions, which was never done before. A detailed friction modeling at the tool-chip and tool-work interfaces is also carried by coupling sticking and sliding frictions. Experiments and simulations have been performed for machining of AISI 4340 steel using tungsten carbide tooling and the simulation results under increasing limit shear stress have been compared to experiments. The influence of limiting shear stress on the tool-chip contact friction was explored and validity of friction modeling approaches was examined. The results presented in this work not only provide a clear understanding of friction in FEM modeling of machining but also advance the process knowledge in machining.     

Multi-objective optimization of oblique turning operations using finite element model and genetic algorithm

Multi-objective optimization of oblique turning operations while machining AISI H13 tool steel has been carried out using developed finite element (FE) model and multi-objective genetic algorithm (MOGA-II). The turning operation is optimized in terms of cutting force and temperature with constraints on required material removal rate and cutting power. The developed FE model is capable to simulate cutting forces, temperature and stress distributions, and chip morphology. The tool is modeled as a rigid body, whereas the workpiece is considered as elastic–thermoplastic with strain rate sensitivity and thermal softening effect. The effects of cutting speed, feed rate, rake angle, and inclination angle are modeled and compared with experimental findings. FE model is run with different parameters with central composite design used to develop a response surface model (RSM). The developed RSM is used as a solver for the MOGA-II. The optimal processing parameters are validated using FE model and experiments.     

Determination of flow stress of thin-walled tube based on digital speckle correlation method for hydroforming applications

The flow stress, used to describe the plastic deformation behavior of thin-walled tube, is one of the most important parameters to ensure reliable finite element simulation in the tube hydroforming process. In this study, a novel approach of on-line measurement based on digital speckle correlation method is put forward to determine flow stress of thin-walled tube. A simple experimental tooling is developed and free-bulged tests are performed for 304 stainless steel and H62 brass alloy tubes. An analytical approach is proposed according to the membrane theory and the force equilibrium equation. The developed method is validated by means of FE simulations. The results indicate that the present method is acceptable to define the flow stress in the tube hydroforming process.     

Positioning and Orienting a Drill Axis on a Curved Surface

A novel technique, referred to as a vector setting in the aerospace industry, has been developed for positioning and orienting drilling bushes on curved surfaces. The position and orientation of holes and their axes in parts and tooling in the aerospace industry must conform to strict tolerances; however, the process of locating and orienting the bushes in drilling plates having curved surfaces is slow and time consuming. This is because the existing process used is a trial and error one, and past research in automated drilling in the aerospace industry has not covered this area. A prototype device has been developed which reduces the setting time. The device has two angular adjustments, which are computed using specially written software. The device is used in conjunction with a 3D spatial measurement system in order to determine reference points on the part or tooling and the device. Experimental results on a prototype indicate a substantial time saving as well as good accuracy in orienting the drill axis at a given point on a surface.     

FINITE ELEMENT ANALYSIS FOR CHIP FORMATION IN HIGH SPEED TURNING OPERATIONS BY ARBITRARY LAGRANGIAN EULERIAN METHOD

A two-dimensional finite element (FE) model for the high speed turning operations when orthogonally machining AISI H13 tool steel at 49HRC using poly crystalline cubic boron nitride (PCBN) is described. An arbitrary Lagrangian Eulerian (ALE) method has been adopted which does not need any chip separation criteria as opposed to the traditional Lagrangian approach. Through FE simulations temperature and stresses distributions are presented that could be helpful in predicting tool life and improving process parameters. The results show that high temperatures are generated along the tool rake face as compared to the shear zone temperatures due to high thermal conductivity of PCBN tools.     

A comparison of methods to evaluate the behavior of finite element models with rough surfaces

Finite element (FE) modeling of rough surfaces is becoming increasingly common. However, the quality of the assumptions being made in these models, and thus the quality of the models themselves, is often unclear. Decisions about the geometry of the surface to be modeled, including the size of the surface to be modeled, the lateral resolution of the measured surface data to be used, and the formulation of the probabilistic surface to be used, can have a significant effect on a model's behavior. Similarly, varying model parameters, including the FE mesh density, can change the results by a factor of three or more. This work examines some of the metrics that can be used to evaluate the influence of these assumptions and parameters on FE models with rough surfaces and discusses the relative merits of each option. In particular, qualitative comparison of result plots, quantitative comparison and convergence of results parameters, qualitative and quantitative comparison of distributions of result values over various model dimensions, and more sophisticated comparison techniques inspired by image and signal processing are discussed.