轴对称件超塑约束胀形中的摩擦效应

尽管超塑胀形作为一种金属成形方法正日渐受到世界各国的普遍关注，但对超塑约束胀形理论的研究报道却还很少，尤其对胀形过程的有限元模拟研究就更为罕见。针对这种情况，采用大变形刚粘塑性有限元法模拟了轴对称零件向圆筒形凹模内超塑约束胀形的变形过程，着重研究了工具工件之界面摩擦对胀形件厚度分布不均匀性和胀形板料向凹模角部充填性的影响．结果表明，随着摩擦的降低，胀形件的侧向较厚部分能有所减薄，可以改善整个胀形件的厚度均匀性，但当摩擦因子Ａｍ≤０．２（相当于摩擦系数μ≤０．１２）时，胀形件极顶部分的减薄过大；摩擦较小时，胀形板料向凹模角部的充填性较好；在考虑到极点附近厚度适度减薄和胀形板料对凹模角部充填性好的前提下，工艺上应当适当减小摩擦，其最佳状态是μ值约为０．３．为了检验所用刚粘塑性有限元法模拟的可靠性，将计算结果与试验结果作了对比，发现两者相当吻合。     

变形-损伤耦合的起塑性恒压轴对称充模胀形的有限元模拟

采用大变形刚粘塑性有限元法模拟超塑性恒压轴对称充模胀形过程、分析了模具几何参数及材料参数对胀形过程中材料的流变行为、胀形制许厚度分布和成形时间的影响规律。给出了质点的流动轨迹、不同时刻制件的剖面形状及应力、应变分布；基于修正的Gurson粘塑性势推导了内部空洞体积分数累积增大模型并据此进行了变形-损伤耦合计算．     

考虑界面滑移效应的组合裂纹梁弯曲解析解

将上部子梁的裂纹等效为线性扭转弹簧,考虑组合梁连接面的滑移位移,建立了以组合裂纹梁挠度和滑移位移为基本未知量的组合裂纹梁弯曲变形一维数学模型．利用Laplace变换及其逆变换,给出了组合裂纹梁弯曲变形一维数学模型的解析通解．在此基础上,研究了均布载荷作用下简支组合裂纹梁的弯曲变形问题,数值分析了连接面剪切刚度、裂纹深度、数目和位置等参数对组合裂纹梁弯曲变形的影响,结果表明：在裂纹处,组合裂纹梁挠度曲线存在尖点,而横截面转角曲线存在跳跃,且随着裂纹数目和深度的增加,挠度和横截面转角跳跃值增大;随着连接面剪切刚度的增加,挠度和横截面转角减小,并最终趋于定值．并且,随着组合梁跨高比的增加,连接面剪切刚度对梁挠度影响逐渐减弱．     

变形—损伤耦合的超塑性恒压轴对称充模胀形的有限元模拟

采用大变形刚粘塑性有限元法模拟超塑性恒压轴对称充模胀形过程，分析了模具几何参数及材料参数对胀形过程中材料的流变行为、胀形制件厚度分布和成形时间的影响规律，给出了质点的流动轨迹，不同时刻制件的剖面形状及应力、应变分布；基于修正的Ｇｕｒｓｏｎ粘塑性势推导了内部空洞体积分数累积增大模型并据此进行了变形－损伤耦合计算。     

铝合金-泡沫铜“三明治”结构自冲铆接可连接性研究

为了探究自冲铆技术应用于铝合金-泡沫铜"三明治"夹层结构的可连接性,以1.0mm和1.5mm两种厚度的泡沫铜作为夹层板,通过试铆实验分析接头的可连接性,基于剖面直观检测法观察接头的成形质量,通过静力学实验分析接头的静力学性能及失效机理.研究表明:自冲铆接可以实现铝合金泡沫铜夹层板的有效连接,泡沫铜夹层使接头残余底厚增大,提高了接头的静失效载荷,1.5mm厚的泡沫铜使自冲铆接头静失效载荷增加7.7%,泡沫铜越厚对接头性能影响越明显.     

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。     

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     

超塑性材料约束胀形中的空洞损伤与变形局部化

将含有二阶段空洞长大模型的本构关系引入大变形刚黏塑性有限元中，研究了空洞敏感材料向锥台形凹模内超塑约束胀形时空洞化损伤与变形局部化行为，详细阐述静水背压Ｐｈ、初始空洞长大速率β＿０以及模具几何形状（锥角θ，模腔高度Ｈｐ）对局部化以及空洞断裂行为的影响，给出实现完全贴模条件下Ｐｈ－θ，Ｐｈ－β＿０，Ｈｐ－θ以及Ｐｈ－Ｈｐ间临界关系。     

精密金属异型挤压塑性成形共形上限解及模腔优化

针对异型材精密挤压塑性成形及模腔建模理论的焦点课题，借助共形映射理论和金属塑性成形理论成果，将异型材截面域的金属挤压三维塑性流动转化为二维轴对称成形问题，建立了金属异型塑性流动的流函数、应变速度场和模具模腔等数学解析模型，应用能量上限原理，以含有对称轴叶形和六边形截面域的挤压型材模腔为例，求解了模腔优化参数，使优化模腔曲面的CAD／CAM一体化技术目标成为可能．     

考虑横向剪切变形和旋转惯性的层合正交异性球壳的动态响应

本文建立了计及横向剪切变形的旋转惯性的复合材料轴对称层合圆柱正交异性球壳的运动方程。在此基础上，用有限差分法计算了球壳在轴对称动力载荷下的动态响应，并讨论了材料参数、结构参数和横向剪切变形的影响。     

Operator-split damage-plasticity applied to groove forming in food can lids

This paper presents a numerical–experimental analysis of damage engineering applied to a well-known industrial problem. Many food cans are manually opened by raising a tab on the lid, thus initiating a crack, which is propagated along a circumferential groove. The influence of the groove geometry and depth on the opening force and the resistance against premature opening is investigated for some packaging materials, by making use of dedicated experimental techniques and an operator-split damage-plasticity framework. Attention is focused on a small part of the groove at a location halfway the circular crack-path, 90⁰ from the crack initiation point. First, the groove manufacturing is analyzed by pressing a punch into a thin sheet of the material. Grooved specimens are loaded in tension, simulating the internal pressure during sterilization, and in shear, simulating the opening. Experiments have been carried out using a miniaturized tensile/compression stage located in the objective field of an optical microscope. For the computational analysis, an operator-split damage-plasticity model is proposed, where ductile damage is easily operated in conjunction with standard plasticity models. Simulations are done within a geometrically non-linear context, using a hypo-elasto-plastic material model with non-linear hardening and a contact algorithm to simulate the contact bodies in the groove forming process. An arbitrary–Lagrange–Euler (ALE) technique and adaptive remeshing are used to assure mesh quality during the large deformation process. The operator-split procedure used for the solution of the governing equations, allows to make easy use of a non-local damage operator as an extra feature within a commercial FEM package. Experimental results reveal that a reduction up to 20% for the opening force with unchanged pre-opening resistance can be reached with the use of an asymmetric punch for the groove forming. Numerical and experimental results are in good agreement. Simulations show that the industrial process of can lid production can be optimized considerably by controlling damage evolution in the first stage of the process.     

High Speed Blanking: An Experimental Method to Measure Induced Cutting Forces

A new blanking process that involves punch speed up to 10 ms ^?1 has obvious advantages in increased productivity. However, the inherent dynamics of such a process makes it difficult to develop a practical high speed punch press. The fracture phenomenon governing the blanking process has to be well understood to correctly design the machine support and the tooling. To observe this phenomenon at various controlled blanking speeds a specific experimental device has been developed. The goal is to measure accurately the shear blanking forces imposed on the specimen during blanking. In this paper a new method allowing the blanking forces to be measured and taking into account the proposed test configuration is explained. This technique has been used to determine the blanking forces experienced when forming C40 steel and quantifies the effect of process parameters such as punch die clearance, punch speed, and sheet metal thickness on the blanking force evolution.     

An extended Marciniak-Kuczynski model for anisotropic sheet subjected to monotonic strain paths with through-thickness shear

Some metal sheet forming processes may induce an amount of plastic shear over the sheet thickness. This paper investigates how formability of anisotropic sheet metal is affected by such through-thickness shear (TTS). The Marciniak-Kuczynski (MK) model framework, a commonly used analytical tool to predict the limit of sheet formability due to the onset of localized necking, is extended in this paper in order to explicitly account for TTS in anisotropic metal sheets. It is a continuation of previous work by the present authors (Eyckens et al., 2009), in which TTS is incorporated for isotropic sheet. This is achieved by the introduction of additional force equilibrium and geometric compatibility equations that govern the connection between matrix and groove in the MK model. Furthermore, in order to integrate plastic anisotropy, a material reference frame available in recent literature is incorporated, as well as a particular model for anisotropic yielding that relies on virtual testing of anisotropic properties (Facet plastic potential), since out-of-plane anisotropy related to TTS cannot be measured experimentally.It is found that formability may be increased by TTS, depending on the direction onto which it is imposed by the forming process. TTS is thus a relevant aspect of the formability in, for instance, sheet forming processes in which sliding contact with friction between sheets and forming tools occur.     

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。     

Effects of Geometry and Dimension of Specimen and Rig on Small Punch Creep Property

The purpose of this study was to examine the effects of the geometries and dimensions of the rig and specimen of a small punch (SP) test on the determined creep property. The SP creep property of a specimen was evaluated using finite element analysis by varying the specimen thickness and diameter, diameter of the spherical and hemispherical indentation punches, inner diameter of the lower die, and dimensions of the chamfer of the lower die. We observed that the rupture time decreased with decreasing specimen thickness and punch diameter and with increasing chamfer size and inner diameter of the lower die. Under similar analytical conditions of static average equivalent stress in steady state, the SP creep curves reasonably agreed even in the case where the specimens or rigs have different geometries, which implied the possibility of direct comparison of the test results obtained from specimens and rigs with different dimensions and geometries.     

Springback compensation in deep drawing applications

This work deals with the problem of springback compensation in sheet metal forming. Satisfactory results can be achieved by performing “die compensation”: the die is modified pretending to obtain a different configuration at the end of the punch stroke, but in order that the final piece coincides with the desired one after the deformation due to springback. Empirical die compensation has nowadays been replaced by numerical simulation, but the inverse problem that needs to be solved is non-trivial since the transformation from the modified geometry of the die and the final piece obtained from it implies a very complex FEM simulation. In this work we set the whole process of springback compensation on solid physical and mathematical grounds. An optimization algorithm based on the Gauss-Newton method is proposed to deliver automatic die compensation and its performance is investigated on some test cases.     

Reexamination of the solder ball shear test for evaluation of the mechanical joint strength

Ball shear tests were investigated in terms of the effects of test parameters, i.e., shear height and shear speed, with an experimental and non-linear finite element analysis for evaluating the solder joint integrity of area array packages. Two representative Pb-free solders were examined in this work: Sn–3.5Ag and Sn–3.5Ag–0.75Cu. The substrate was a common solder mask defined (SMD) type with solder bond pad openings of 460 μm in diameter. The microstructural investigations were carried out using scanning electron microscopy (SEM), and the intermetallic compounds (IMCs) were identified with energy dispersive spectrometry (EDS). Shear tests were conducted with the two varying test parameters. It was observed that increasing shear height at a fixed shear speed has the effect of decreasing shear force for both Sn–3.5Ag and Sn–3.5Ag–0.75Cu solder joints, while the shear force increased with increasing shear speed at fixed shear height. Shear heights that were too high had some negative effects on the test results such as unexpectedly high standard deviation values or shear tip sliding from the solder ball. Low shear height conditions were favorable for screening the type of brittle interfacial fractures or the degraded layers in the interfaces.     

The shear fracture of dual-phase steel

Unexpected fractures at high-curvature die radii in sheet forming operations limit the adoption of advanced high strength steels (AHSS) that otherwise offer remarkable combinations of high strength and tensile ductility. Identified as “shear fractures” or “shear failures,” these often show little sign of through-thickness localization and are not predicted by standard industrial simulations and forming limit diagrams. To understand the origins of shear failure and improve its prediction, a new displacement-controlled draw-bending test was developed, carried out, and simulated using a coupled thermo-mechanical finite element model. The model incorporates 3D solid elements and a novel constitutive law taking into account the effects of strain, strain rate, and temperature on flow stress. The simulation results were compared with companion draw-bend tests for three grades of dual-phase (DP) steel over a range of process conditions. Shear failures were accurately predicted without resorting to damage mechanics, but less satisfactorily for DP 980 steel. Deformation-induced heating has a dominant effect on the occurrence of shear failure in these alloys because of the large energy dissipated and the sensitivity of strain hardening to temperature increases of the order of 75 °C. Isothermal simulations greatly overestimated the formability and the critical bending ratio for shear failures, thus accounting for the dominant effect leading to the inability of current industrial methods to predict forming performance accurately. Use of shell elements (similar to industrial practice) contributes to the prediction error, and fracture (as opposed to strain localization) contributes for higher-strength alloys, particularly for transverse direction tests. The results illustrate the pitfall of using low-rate, isothermal, small-curvature forming limit measurements and simulations to predict the failure of high-rate, quasi-adiabatic, large-curvature industrial forming operations of AHSS.     

Generalised forming limit diagrams showing increased forming limits with non-planar stress states

The forming limit diagram and its associated analytical and experimental techniques has been widely used for 40 years with the assumption that sheet deformation occurs inplane-stress. Some hydro-forming type processes induce significant normal stress across the workpiece and this has led to a small number of extended formability analyses. However, recent work on the incremental sheet forming process which is known to give higher formability than conventional sheet pressing has shown that the repeated passage of a tool over the sheet leads to significant through-thickness shear strains being induced in the workpiece. Accordingly this paper explores the forming limits of sheet forming processes which induce any possible proportional loading, including all six components of the symmetric stress tensor. Marciniak and Kuczyinski’s famous (1967) analysis is extended to allow such loading, and a new generalised forming limit diagram (GFLD) is proposed to allow visual representation of the resulting forming limit strains. The GFLD demonstrates that forming limits can be increased significantly by both normal compressive stress and through-thickness shear. This increased formability is confirmed by experiments on a specially designed ‘linear paddle testing’ apparatus in which a conventional uniaxial test is augmented by the action of a paddle that ‘strokes’ the sample while also applying a normal force. Tests on the rig show that the paddle action leads to enhanced engineering strains at failure up to 300%. The insight gained in this paper is significant for process analysts, as it may explain existing discrepancies between prediction and experience of forming limits, and is important for designers who may be able to use it to expand process operating windows.     

Marciniak–Kuczynski type modelling of the effect of Through-Thickness Shear on the forming limits of sheet metal

The Marciniak–Kuczynski (MK) forming limit model is extended in order to predict localized necking in sheet metal forming operations in which Through-Thickness Shear (TTS), also known as out-of-plane shear, occurs. An example of such a forming operation is Single Point Incremental Forming. The Forming Limit Diagram (FLD) of a purely plastic, isotropic hardening material with von Mises yield locus is discussed, for monotonic deformation paths that include TTS. If TTS is present in the plane containing the critical groove direction in the MK model, it is seen that formability is increased for all in-plane strain modes, except equibiaxial stretching. The increase in formability due to TTS is explained through a detailed study of some selected deformation modes. The underlying mechanism is a change of the stress mode in the groove that results in a delay of the onset of localized necking.