材料参数及工艺参数对盒形件成形性能的影响研究

主要研究了材料参数及工艺参数对盒形件成形性能的影响 ,通过正交试验和计算机数值模拟相结合 ,确定了最佳的参数组合方式 ,并用该最优数据进行实际冲压 ,得到的结果与最优模拟结果比较吻合     

48 V/50 Ah磷酸铁锂电池组热仿真

目的基于COMSOL Multiphysics软件对锂离子电池组进行热耦合仿真研究,正确辨识电池的有关热物性参数。方法首先确立锂离子电池组仿真的热模型,关于锂离子电池传热模型中涉及的热物性参数,基于不同形状大小的加热片对电池在绝热环境下进行加热,将电池各热物性参数的获取相互解耦,通过对传热模型方程以及边界条件的简化辨识出锂离子电池的热物性参数。最后,基于已确立的锂离子电池热仿真理论基础以及辨识出的相关参数,运用COMSOLMultiphysics仿真软件对锂电池单体和电池组在不同充电倍率下的温度场进行仿真分析,并进行实验验证模型的精确程度。结果根据仿真结果和实验数据的对比分析,基于COMSOLMultiphysics仿真软件可以较为准确地对锂离子电池组壳体表面和内部的温度场进行描述,误差不超过0.5℃。结论在满足一定误差精度范围内,对锂离子电池组热管理系统进行分析和设计时,通过仿真得到的结果就可以为其提供参考和指导。     

某离心机模型辨识与仿真

目的辨识某离心机的加速度控制模型,并开展控制系统仿真和优化。方法实测某离心机运行时的转速、电压、电流等,对保载和加速状态的电流进行拟合,进而分析保载阻力、等效转动惯量等模型参数。建立离心机加速度控制系统Simulink仿真模型,进行仿真试验。结果基于辨识的模型参数进行仿真的结果与真实系统试验的结果很接近,为控制系统优化、各种试验能力和误差预估提供了可信的模型。结论采用的辨识方法可行,辨识的参数正确,离心机仿真模型运行快速正确,可供相关离心机辨识和仿真参考。     

基于遗传算法的综合热能管理系统代偿优化

在SIMULINK平台下搭建了飞机综合热能管理系统仿真模型,并利用遗传算法对其可控参数如发动机引气的阀门开度、冲压空气进口面积和液体环路的流量等进行在不同飞行状态下的寻优,使得飞机在满足温度等要求的情况下起飞总重的代偿较小。结果表明,利用智能算法可以实现这种复杂系统的参数优化,从而提高飞机燃油经济性。     

含能材料反应釜温度模型仿真辨识

目的验证一种基于遗忘因子最小二乘法(FFRLS)的含能材料反应釜温度预测模型辨识方法的正确性和有效性。方法首先利用基于机理建模方法对系统模型进行分段处理,并得到其具体结构,然后结合历史数据,利用FFRLS对系统模型参数进行辨识,最后得到含能材料反应釜温度仿真模型。结果在Matlab仿真平台上对该方法的正确性和有效性进行验证,模型参数慢时变状态下该方法辨识参数的模型参数均方根误差(RMSE)皆小于10%,模型参数突变状态下,参数RMSE最小为5.89%,最大为18.69%。结论该方法能准确、有效地对含能材料反应釜温度模型进行辨识。     

低温极端载荷作用下船艏结构损伤演化过程研究

目的 掌握船舶在极地低温极端环境中航行时,船舶艏部结构遭遇冰山等极端载荷作用下的主要参数对结构损伤演化过程的影响,揭示船舶艏部结构的失效机理。方法 以船舶艏部结构为研究对象,基于数值仿真方法,开展不同碰撞场景、环境温度、撞击速度、冰体塑性应变、船体材料本构模型、撞击角度等参数对结构损伤的影响研究。结果 建立了数值仿真简化模型,获得了不同参数对结构损伤的影响规律。结论 材料模型对船体结构损伤的影响较小。随着航速增加、撞击角度增大,船体损伤范围增大。随着船体材料性能增强,撞击区刚度增大,船体结构损伤范围减小。形成的损伤演化模拟方法可为极地极端环境下船舶结构损伤演化分析提供技术手段。     

汽车门槛内板零件冲压数值模拟及参数优化

针对汽车覆盖件冲压变形复杂,成形工艺参数难以确定等特点,基于DYNAFORM软件对汽车门槛内板零件的拉延成形过程,及不同工艺参数对成形结果的影响进行了研究。用优化的工艺参数进行模拟验证,从而为工艺设计和试模提供理论指导。     

基于MATLAB仿真的井下变压器参数设置研究

针对井下变压器的特点,本文提出了用simulink仿真时,变压器模块参数获取方法。并通过搭建变压器的仿真模型,对变压器进行空载和短路试验,仿真结果证明了所给公式的正确性。     

鼓包竖板拉延成形的有限元模拟

简单介绍了铝合金板的冲压成形性能,应用有限元模拟技术,分别采用普通钢板和铝合金6009对鼓包竖板的拉延成形进行了有限元模拟,对比结果,分析了差异产生的原因。应用等效拉延筋,对材料采用铝合金板的模拟结果进行改进,较好地改善了起皱缺陷,最终提出了合理的工艺造型方案,为指导和改进拉延模结构设计提出可靠的理论依据及相关设计参数。同时,为该零件确定了合适的材料。     

大型车车身覆盖件冲压成形特征分析及选材研究

为满足大型车身覆盖件冲压成形要求并实现钢板与零件的对路供应 ,必须在深入解析零件成形特征的基础上 ,确定高应变部位的成形敏感材料参数。在材料力学性能测试和成形极限分析的基础上 ,对侧围外板的冲压成形特征和成形敏感参数进行了分析。结果表明 :侧围外板零件高应变部位的变形方式为胀形 深拉延变形 ,n值和r值为影响侧围外板零件成形的主要材料敏感参数     

A New Approach to Predicting Forming Limits of Steel Sheet

A yield criterion utilizing five independent material parameters for representing the yield locus was proposed by Hill in l993. This paper describes an attempt to analyze forming limits of aluminum-killed (AK) steel sheet metal based on this criterion in conjunction with the M-K approach. Comparison of the predicted results with experimental data indicates that localized necking can be characterized only to a limited extent. However, material properties do not remain constant, but are deformation history dependent. Inclusion of deformation-dependent parameters in the analysis demonstrates a significant positive influence on forming limits. Comparison of predicted results with the experimental data underscores that the consideration of history-dependent material properties can improve forming limit predictions considerably.     

采用薄膜模型模拟三维板料成形过程

此文基于有限变形理论建立了三维金属板料成形过程的弹塑性有限元数学模型。数学模型采用物质坐标系中的Total Lagrange描述、J_2型本构方程、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的摩擦采用近似的库仑摩擦定律以改善计算的收敛性。为简化计算采用薄膜单元。采用根据此模型编制的程序模拟了机油收集器基本件的成形过程,并与实验结果进行了对比。     

Prediction of flange wrinkling in deep drawing process using bifurcation criterion

Surface distortions in the form of wrinkles are often observed in sheet metals during stamping and other forming operations. Because of the trend in recent years towards thinner, higher-strength sheet metals, wrinkling is increasingly becoming a more common and troublesome mode of failure in sheet metal forming. The prediction and prevention of wrinkling during a sheet forming process are important issues for the design of part geometry and processing parameters. This paper treats the phenomenon of flange wrinkling as a bifurcated solution of the equations governing the deep drawing problem when the flat position of the flange becomes unstable. Hill’s bifurcation criterion is used to predict the onset of flange wrinkling in circular and square cup drawing. In particular, the maximum cup height that can be drawn without the onset of flange wrinkling is predicted for the given set of process parameters. A parametric study of the maximum cup height is also carried out with respect to various geometric, material and process parameters. Finite element formulation, based on the updated Lagrangian approach, is employed for the analysis. The incremental logarithmic strain measure, which allows the use of a large incremental deformation, is used. The stresses are updated in a material frame. The material is assumed to be elastic–plastic, strain hardening, yielding according to an anisotropic yield criterion of Barlat et al. (2005) [23] (named as Yld2004-18p). Isotropic power law hardening is assumed. Inertia forces are neglected due to small accelerations. Modified Newton–Raphson iterative technique is used to solve the nonlinear incremental equations.     

External force-assisted laser forming process for gaining high bending angles

Laser forming process is used in forming and bending of metallic and non-metallic sheets. Laser beam irradiation causes a localized temperature increase and a localized mechanical strength decrease. In this article, an external mechanical force is added to a laser beam irradiation, which is called external force-assisted laser forming process, to gain a 90-degree bending angle. Furthermore, Numerical simulation of the process is performed to achieve a good understanding of the process. Simulation results show that more than two-third of the final forming is due to the laser beam irradiation. Equivalent plastic strain values during laser forming and external force-assisted laser forming processes are compared. Results show that equivalent plastic strain in laser forming process increases in a step pattern, with increasing in scan pass numbers. This occurs because when the laser beam irradiates on the sheet surface, it reduces the yield strength of the sheet. Equivalent plastic strain in external force-assisted laser forming process has an oscillatory step nature. This attributes to simultaneous effects of strain hardening and thermal induced reduction of yield strength of the sheet. Simulations were in good accordance with experiments.     

Analytical prediction of stepped feature generation in multi-pass single point incremental forming

Single point incremental forming (SPIF) is a new sheet metal forming process characterized by higher formability, product independent tooling and greater process flexibility. The inability of conventional single pass SPIF to form vertical walls without failure is overcome by forming multiple intermediate shapes before forming the final component, i.e., multi-pass single point incremental forming (MSPIF). A major issue with MSPIF is significant geometric inaccuracy of the formed component, due to the generation of stepped features on the base. This work proposes analytical formulations that are shown to accurately and quantitatively predict the stepped feature formation in MSPIF. Additionally, a relationship is derived among the material constants used in these analytical equations, the yield stress and thickness of the blank material, such that the computational effort required for the calibration of these constants can be minimized. Finally, the physical effects of yield stress and sheet thickness on the rigid body translation are further discussed.     

金属板材成形的静力隐式有限元分析与程序设计

阐述了用于板材成形过程静力隐式数值模拟的弹塑性大变形有限元方法 ,基于给出的方法编制了板材成形过程数值模拟软件 ,并对矩形板的液压胀形进行了有限元分析 ,计算结果与典型的实验结果吻合很好。对球形模具拉伸成形过程进行了数值模拟 ,给出了计算结果     

Dimpling process in cold roll metal forming by finite element modelling and experimental validation

The dimpling process is a novel cold-roll forming process that involves dimpling of a rolled flat strip prior to the roll forming operation. This is a process undertaken to enhance the material properties and subsequent products’ structural performance while maintaining a minimum strip thickness. In order to understand the complex and interrelated nonlinear changes in contact, geometry and material properties that occur in the process, it is necessary to accurately simulate the process and validate through physical tests. In this paper, 3D non-linear finite element analysis was employed to simulate the dimpling process and mechanical testing of the subsequent dimpled sheets, in which the dimple geometry and material properties data were directly transferred from the dimpling process. Physical measurements, tensile and bending tests on dimpled sheet steel were conducted to evaluate the simulation results. Simulation of the dimpling process identified the amount of non-uniform plastic strain introduced and the manner in which this was distributed through the sheet. The plastic strain resulted in strain hardening which could correlate to the increase in the strength of the dimpled steel when compared to plain steel originating from the same coil material. A parametric study revealed that the amount of plastic strain depends upon on the process parameters such as friction and overlapping gap between the two forming rolls. The results derived from simulations of the tensile and bending tests were in good agreement with the experimental ones. The validation indicates that the finite element analysis was able to successfully simulate the dimpling process and mechanical properties of the subsequent dimpled steel products.     

LDR and hydroforming limit for deep drawing of AA5754 aluminum sheet

The goal of the research was to determine the limits and conditions in which the sheet hydroforming process provides a significant advantage over stamping in deep drawing of AA5754 aluminum sheets. Specifically, the maximum draw depth achievable by stamping, warm stamping (WF), sheet hydroforming (SHF), and sheet thermo-hydroforming (THF) of AA5754 aluminum alloy were quantified through experimental and computational modeling. A limited number of forming experiments were conducted with AA5754 aluminum sheets using a cylindrical punch and counteracting fluid at different temperatures and pressures. Several parameters, such as force–displacement, hydroforming pressure and temperature, and the maximum draw depth prior to wrinkling or tearing were measured during the forming process to make comparisons with simulations. The computational study included the simulation of stamping, WF, SHF and THF of AA5754 aluminum sheet with the LS-Dyna code, and the Barlat 2000-2d yield function with temperature-dependent coefficients. To predict the onset of wrinkling and tearing, the numerically generated, temperature-dependent forming limit diagrams (FLDs) based on the Barlat 2000-2d yield function were used. It was found that compared with stamping, SHF and THF can achieve more than 100% deeper draw depths with AA5754 aluminum sheet. The stamping simulations were used also to calculate the optimum blank size and die corner radii for the limiting draw ratio (LDR). The LDR was found to be very sensitive to the punch and die corner radii used in the experiments, which represent the curvature of character lines in an actual part. The LDR for AA5754 aluminum sheet was found to be 1.33 and 2.21 for sharp and round die corner radii, respectively. Overall, it was concluded that SHF is most ideal for deep drawing of aluminum sheets with sharp radii features. With the additional drawability provided by SHF, the automotive industry would be able to make difficult-to-form aluminum parts that cannot be stamped without product concessions such as increasing the die radii.