板料三维成形过程的有限元数值模拟

基于有限变形理论建立了三维金属板料成形过程的刚塑性有限元数学模拟,该数学模型采用物质坐标系中的Ｕｐｄａｔｅ－Ｌａｇｒａｎｇｅ描述,等向强化假设,考虑了板料的厚向异性,对于金属板料与模具有摩擦采用近似的库仑摩擦定律以改善计算的收敛性。为简经计算采用薄膜单元,并根据此模型编制程序。     

冲压过程模拟的接触与摩擦关系数值方法

文中简介采用非经典算法求解板件冲压过程数值模拟的基本思想；就与模具间接触与摩擦关系的处理作重点论述，并给出算例。     

板材成形的计算机辅助工程系统

板材成形同时包含大变形、（粘）塑性、接触、摩擦等多种非线性因素耦合,刊用有限元法在计算机上模拟出板材从坯件到成品的全过程并加以图形显示,进而研究影响成形的各种因素,可以为板材成形的设计和生产提供可靠依据．本文介绍板材成形的计算机辅助工程系统（简称ＣＡＥ系统）的组成,并对成形数值模拟中的有限元格式、接触与摩擦问题、拉伸筋的考虑方法以及回弹的计算方法做了简单介绍．      

楔形模宽条料超塑性挤压非局部摩擦分析

为了考虑金属材料表面微凸结构对模具与工件接触区域上的非局部摩擦效应,在楔形模宽条料超塑性挤压加工问题中,首次采用Oden等提出的非局部摩擦定律代替经典的库仑摩擦定律,利用主应力法或工程法建立了相应问题的积微分形式的力平衡方程.在简化的情况下,采用摄动法求得所论问题的近似解,并分析了影响应力的非局部效应的相关因素.     

金属板条在圆柱形模中弯曲成形的大变形有限元分析

本文采用大变形弹塑性有限元法对金属板条在柱形模中的压弯成形过程进行了数值模拟，并与实验进行了比较，首先给出了纠正的拉格朗日有限元公式和基于弹塑性乘法分解的超弹性塑性本构关系。对接触摩擦问题的处理采用了罚函数法。通过对数值结果的分析得出了些对弯曲工艺的设计有指导价值的结论。     

厚钣金件压弯翻边与回弹的数值研究

在独立研制的板材冲压成形性分析软件KMAS中，组入可有效模拟厚钣金件压弯成形与回弹变形的三维退化曲壳单元模型，简述了考虑凹，凸模间隔可变的基于有限元网格双面接触算法以及回弹的处理技术，数值研究了铁路客车牵引架厚钣金件压弯翻边与回弹变形过程，并将压弯过程模拟结果与国外基于单面接触算法的商品化软件的模拟结果以有实验结果进行比较，最后，给出了该类问题回弹量的预示方法。     

304L/Q235B大面积金属板爆炸焊接物质点法模拟分析

大面积金属板材304L/Q235B的爆炸焊接过程涉及炸药爆轰、金属板材的高速碰撞和塑性变形等。采用有限元法计算模拟这个问题时,网格单元会发生扭曲畸变现象,导致计算精度下降,甚至出现单元负体积而使计算终止,并且炸药爆轰形成气体产物飞散过程也很难模拟。为了能模拟大面积金属板材的爆炸焊接整个过程并获得合理的技术工艺参数,采用物质点法进行三维数值模拟分析。物质点法作为一种无网格法,在模拟冲击动力学问题中主要采用显式积分算法。通过将拉格朗日质点单元与固定的欧拉背景网格相结合,可以实现爆炸焊接的复板与基板的高速碰撞、炸药滑移爆轰、金属板面的塑性变形过程的数值模拟,并给出爆炸复合板材的形变、有效塑性应变和复板与基板的碰撞速度的计算结果。采用物质点法模拟的复合板材变形与爆炸焊接实验结果基本一致。计算复板与基板的碰撞速度这个重要的物理参数时,物质点法与Richter理论公式的相对误差不超过13%。数值计算和实验结果表明,物质点法在数值精度和计算效率方面具有优势,物质点法是研究金属焊接爆炸问题的一种有效数值方法。     

板带轧制过程中的三维接触摩擦模型

为解决压力加工中工具与工件间的接触摩擦问题，根据金属流动对摩擦的反作用，在轧辊和工件之间引入了一层极薄的摩擦单元并将其编入三维弹塑性大变形有限元程序。通过调节摩擦元尺寸厚度和β因子，实现了对薄板轧制过程中间介质的几何尺寸模拟和物理特征模拟。该法不用对摩擦力大小、方向及中性点位置进行假定，通过计算能够得到全部有关信息。     

金属板条在圆柱形模中弯曲成形的大变形有限元分析

本文采用大变形弹塑性有限元法对金属板条在柱形模中的压弯成形过程进行了数值模拟,并与实验进行了比较。首先给出了纠正的拉格朗日有限元公式和基于弹塑性乘法分解的超弹性塑性本构关系。对接触摩擦问题的处理采用了罚函数法。通过对数值结果的分析得出了一些对弯曲工艺的设计有指导价值的结论。     

六面体网格再划分过程中畸变和模具干涉单元的处理方法

针对金属体积成形过程中有限元网格畸变和再划分问题,研究了工件网格畸变单元中表面四边形面片分解为三角形面片时的重叠问题,提出了将工件与模具接触区域的工件三角形面片用模具表面三角形面片代替的算法,并给出了接触区域判断、相交点计算、相交三角形环的二次剖分以及融合拼接等关键技术,算法能够很好地描述工件与模具接触区域的形状特征,...     

A hybrid membrane/shell method for calculating springback of anisotropic sheet metals undergoing axisymmetric loading

To reduce the computation cost of finite element analyses aiding die design for sheet metal stamping, a hybrid membrane/shell method was developed to determine the springback of anisotropic sheet metal undergoing axisymmetric loading. The hybrid membrane/shell method uses a membrane model to analyze the stamping operation. The bending/unbending strains and stresses varying through thickness are calculated analytically from the incremental shape determined by the membrane analysis. These bending strains and stresses and the final membrane shape are used with a shell finite element model to unload the sheet and calculate springback. The accuracy of the springback prediction with the hybrid method was verified against the springback of 2036-T4 aluminum and a DQAK steel sheet drawn into a cup. It was found that, in comparison with a full shell model, a minimum of 50% CPU time saving and a comparable accuracy was achieved when the hybrid method was used to predict springback.     

板材多点成形过程的有限元分析

多点成形过程采用静力隐式格式进行数值模拟是比较合适的。本文建立了用于多点成形过程分析的静力隐式弹塑性大变形有限元方法 ,给出了对稳定迭代收敛过程效果较好的板壳有限单元模型、处理多点不连续接触边界的接触单元方法以及增量变形过程中应力及塑性应变计算的多步回映计算方法。基于这些方法编制了计算软件 ,应用该软件进行了矩形板的液压胀形过程及球形模具拉伸成形过程的有限元分析 ,数值计算结果与典型的实验结果及计算结果吻合很好。最后给出了球形、圆柱形目标形状的实际多点成形过程的数值模拟结果。     

Postbifurcation behavior of wrinkles in square metal sheets under Yoshida Test

The stretching of a square sheet along one of its diagonals, called “Yoshida Test”, has been developed to simulate the wrinkling behavior in press forming of steel sheets into autobody panels. The finite deformation, onset of wrinkling, and growth of wrinkles in such a specimen are investigated. Hill's yield criterion for sheet materials having the normal anisotropy and Hill's quasistatic bifurcation criterion are employed. The growth of wrinkles in the finite deformation process is incrementally and numerically determined by a thin shell finite element in a convected coordinate system. The Lagrangian formulation of the thin shell finite element is based on Hill's variational principle for elastic-plastic solids, a modification of Love-Kirchhoff postulates and a quasiconforming element technique. The shell element fulfills the interelement C¹ continuity condition in a variational sense. Reasonable agreements between the present numerical results and available analytical and experimental results are shown.     

Flange earing and its control on deepdrawing of anisotropy circular sheets

The Hill's quadric anisotropy yield function and the Barlat-Lian anisotropy yield function describing well anisotropy sheet metal with stronger texture are introduced into a quadric-flow corner constitutive theory of elastic-plastic finite deformation suitable for deformation localization analysis. And then, the elastic-plastic large deformation finite element formulation based on the virtual power principle and the discrete Kirchhoff shell element model including the yield functions and the constitutive theory are established. The focus of the present research is on the numerical simulation of the flange earing of the deep-drawing of anisotropy circular sheets, based on the investigated results, the schemes for controlling the flange earing are proposed. Supported by NSFC(No. 19832020) and National Automobile Dynamic Simulation Laboratory of China.     

SECTIONAL FINITE ELEMENT ANALYSIS OF COUPLED DEFORMATION BETWEEN ELASTOPLASTIC SHEET METAL AND VISCO-ELASTOPLASTIC BODY

The present paper is devoted to developing a new numerical simulation method for the analysis of viscous pressure forming (VPF), which is a sheet flexible-die forming (FDF) process. The pressure-carrying medium used in VPF is one kind of semisolid, flowable and viscous material and its deformation behavior can be described by the visco-elastoplastic constitutive model. A sectional finite element model for the coupled deformation analysis between the visco- elastoplastic pressure-carrying medium and the elastoplastic sheet metal is proposed. The resolution of the Updated Lagrangian (UL) formulation is based on a static explicit approach. The frictional contact between sheet metal and visco-elastoplastic pressure-carrying medium is treated by the penalty function method. Coupled deformation between sheet metal and visco-elastoplastic pressure-carrying medium with large slip is analyzed to validate the developed algorithm. Finally, the viscous pressure bulging (VPB) process of DC06 sheet metal is simulated. Good agreement between numerical simulation results and experimental measurements shows the validity of the developed algorithm.     

The effect of plastic anisotropy on compressive instability in sheet metal forming

The wrinkling behavior of a thin sheet with perfect geometry is associated with compressive instability. The compressive instability is influenced by many factors such as stress state, mechanical properties of the sheet material, geometry of the body, contact conditions and plastic anisotropy. The analysis of compressive instability in a plastically deforming body is difficult considering all the factors because the effects of the factors are very complex and the instability behavior may show a wide variation for a small deviation of the factors. In this study, the bifurcation theory is introduced for the finite element analysis of puckering initiation and growth of a thin sheet with perfect geometry. All the above mentioned factors are conveniently considered by the finite-element method. The instability limit is found by the incremental analysis and the post-bifurcation behavior is analyzed by introducing the branching scheme proposed by Riks. The finite-element formulation is based on the incremental deformation theory and elastic–plastic material modeling. The finite-element analysis is carried out using the continuum-based resultant shell elements considering the anisotropy of the sheet metal. In order to investigate the effect of plastic anisotropy on the compressive instability, a square plate that is subjected to compression in one direction and tension in the other direction is analyzed by the above-mentioned finite-element analysis. The critical stress ratios above which buckling does not take place are found for various plastic anisotropic modeling methods and discussed. Finally, the effect of plastic anisotropy on the puckering behavior in the spherical cup deep drawing process is investigated. From the results of the finite-element analysis, it is shown that puckering behavior of sheet metal is largely affected by plastic anisotropy.     

Coupled thermoelasticity of functionally graded cylindrical shells

The coupled thermoelastic response of a functionally graded circular cylindrical shell is studied. The coupled thermoelastic and the energy equations are simultaneously solved for a functionally graded axisymmetric cylindrical shell subjected to thermal shock load. A second-order shear deformation shell theory that accounts for the transverse shear strains and rotations is considered. Including the thermo-mechanical coupling and rotary inertia, a Galerkin finite element formulation in space domain and the Laplace transform in time domain are used to formulate the problem. The inverse Laplace transform is obtained using a numerical algorithm. The shell is graded through the thickness assuming a volume fraction of metal and ceramic, using a power law distribution. The results are validated with the known data in the literature.     

三维板料成形过程的显式有限元分析

本文采用基于随动坐标系的假定应变域壳单元及显式有限元格式求解三维板料成形问题。板材料服从Ｈｉｌ各向异性弹塑性准则，板料与模具之间的接触界面由主仆面接触搜寻法处理，接触力由罚参数法计算。文中给出了几个三维成形过程的计算实例。数值算例表明，本文方法具有较高的计算精度和计算效率，可在微机上分析中等复杂程度的成形过程     

A finite element analysis of the flange earrings of strong anisotropic sheet metals in deep-drawing processes

Flange earrings of strong anisotropic sheet metals in deep-drawing process are numerically analyzed by the elastic-plastic large deformation finite element formulation based on a discrete Kirchhoff triangle plate shell element model. A Barlat-Lian anisotropic yield function and a quasi-flow corner theory are used in the present formulation. The numerical results are compared with the experimental ones of cylindrical cup drawing process. The focus of the present researches is on the numerical analysis and the constraining scheme of the flange earring of circular sheets with strong anisotropy in square cup drawing process. The project supported by the National Natural Science Foundation of China (19832020) and Provincial Natural Science Foundation of Jilin, China (200000519)