提高圆筒件极限拉伸系数的控制方法研究

分析了影响板料拉深成形极限拉伸系数因素，指出压边力参数对LDR具有不可忽视的影响，并给出了改造单动液压拉深压边力控制系统提高LDR的方法。     

热水器面罩成形模设计

分析了热水器面罩成形模的设计方案.通过成形时极限变形、成形力以及压边力的计算.在3150kN双动油压机上试出合格产品.     

可调节常压边力拉深模设计

提出了以弹簧或橡胶作为弹性元件压边,可提供常压边力的新结构.采用这种压边方式,不仅可使压边力在拉深过程中保持不变,并能从零至最大设计压边力的范围内进行调节,且适用于不同厚度板坯的压边,故压边装置又具较大的通用性.     

盒形件多点常力压边拉深模设计

对盒形件拉深成形 ,提出了在周向多个位置施加压边力的方法 ,且根据常力压边原理 ,用弹簧和橡胶作弹性元件 ,可根据需要在不同位置施加不同的压边力 ,且每个位置的压边力在拉深过程中保持定值。以此设计的模具所提供的压边力 ,更适合复杂零件的成形 ,也更符合拉深工艺对压边力的要求     

利用神经网络及数值模拟获取变压边力控制曲线

在应用Dynaform、Autoform等板料数值模拟软件的过程中 ,通常需要对压边力施力曲线进行各种预先的设定 ,但如何选定施力模式一直是一个比较棘手的问题 ,在文中利用数值模拟及MATLAB中的神经网络工具箱得出了压边力的最优控制曲线     

板料成形模拟中压边力处理的研究

针对弹性压边建立了一个力学模型 ,用于板料成形的动力显式有限元模拟。以NU MISHEET’93方盒拉深标准考题为例 ,模拟了方盒在不同压边力情况下的起皱情况。数值计算结果表明该模型能有效地模拟弹性压边力 ,并预测工件法兰部位的起皱状况。     

研究拉深过程中压边力值的合理确定

一般在确定压迫力值大小时只考虑拉深系数、坯料厚度,没有考虑选用的润滑剂种类.我们通过实验研究得出:正确的给定拉深过程中的压边力值时不仅要考虑拉深系数、坯料厚度,而且还必须考虑拉深过程中使用的润滑剂种类.该实验研究结果有助于工程技术人员在制定生产现场的工艺时确定最佳压边力范围.     

板料冲压过程的数值仿真与参数优化

采用有限元动态分析技术,采用HILL屈服准则,模拟了板料拉深成形的过程,结合实验拉深进行比较,模拟结果与实验数据符合。应用0.618一维搜索优化方法,在数值模拟中对压边力进行了优化,为实验中压边力的确定提供了参考数据。     

汽车后座椅横梁冲压成形过程的数值模拟

采用数值模拟方法,对某型高强钢汽车后座椅横梁的成形过程进行研究,讨论压边力和拉深筋的变化对该零件成形性能的影响。模拟结果表明,采用合适的压边力和较低的拉深筋阻力系数,可有效提高高强钢的成形性能,获得合格的零件。针对模拟结果中零件出现的缺陷,提出了初步的工艺改进方案。     

薄板拉延成形的固定压边间隙控制方式研究

分析了薄板拉延过程中应用固定压边间隙控制方式的成形特点，指出选择合理的压边间隙量是保证冲压件成形质量的关键。应用有限元数值仿真技术，以NUMISHEET＇99圆柱杯深拉延——反向深拉延标准考题(Benchmark-C)为例，模拟了其成形过程，在仿真结果与KimHyungjong的实验结果较好地吻合的基础上，通过对大量仿真计算结果的分析．提出了薄板多工序拉延成形中采用压边间隙控制方式时合理选择间隙量的方法。     

板材成形新技术及其发展趋势(Ⅰ)

近些年来,面对全球化的竞争,越来越需要小批量、多样化、周期短的新的成形技术.薄板成形技术在成形工艺中占有很重要的地位,其多样化趋势已经变得越来越明显,出现了多种加工方法,它对将来的工业结构和产品的生产技术将是一场革命.文中介绍了变压边力技术、成对液压成形技术、粘介质成形技术、无模分层成形技术等几种柔性化程度高的板材成形技术及其发展趋势.     

基于反向模拟的毛坯外形设计

毛坯外形设计是工艺设计的重要环节 ,它直接影响工件的成形质量。精确计算毛坯外形极其困难 ,目前尚无通用的方法。反向模拟结合了塑性形变理论和有限元技术 ,直接由工件反算出毛坯。文中着重指出反向模拟与一般增量正向模拟的区别 ,对其应用于毛坯设计的原理作了阐述 ,并通过标准考题验证了方法的有效性 ,最后将其应用于一实际生产零件的毛坯外形设计。     

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.     

筒形件无压边圈拉深工艺参数优化设计

通过对筒形件极限拉深系数的影响因素进行分析 ,确定合适的凸凹模圆角半径是提高拉深件质量的重要途径 ,将塑性理论和优化算法相结合 ,以筒形件达到最小的极限拉深系数为优化目标 ,对筒形件无压边圈拉深工艺参数优化设计进行了研究。并且通过具体算例证明了所采用的优化模型及算法是有效的     

Effect of quasi-static prestrain on the formability of dual phase steels in electrohydraulic forming

Dual phase steels derive their name from their microstructure, which consists of islands of martensite surrounded by a ferrite matrix. These steels are increasingly being used in automobile structures in order to reduce weight, improve fuel economy, and maintain crash safety performance. The higher strength grades of dual phase steels, such as DP780 and DP980, often present significant formability challenges in sheet stamping operations, and therefore any technologies which could alleviate these issues would be of significant value to the automotive industry. Electrohydraulic forming (EHF) is based upon the electro-hydraulic effect: a complex phenomenon related to the discharge of high voltage electrical current through a liquid. In EHF, electrical energy is stored in a bank of capacitors and is converted into the kinetic energy needed to form sheet metal by rapidly discharging that energy across a pair of electrodes submerged in a fluid. During such a discharge, a high pressure, high temperature plasma channel is created between the tips of the electrodes. The resulting shockwave in the liquid, initiated by the expansion of the plasma channel, is propagated toward the blank at the acoustic velocity of the fluid, and the mass and momentum of the water in the shock wave accelerates the sheet metal blank toward the die. The objective of this paper is to report the results of formability testing of dual phase steels under three basic conditions: (1) conventional limiting dome height (LDH) testing; (2) starting with a flat blank and using one pulse of EHF to fill the desired die geometry; and (3) starting with a quasi-static preforming step to partially fill the die cavity and then using one pulse of EHF to fill the remaining area of the die cavity. A hybrid process which combines sheet hydroforming (HF) and EHF as described herein has the potential to reduce the cycle time of the EHF process by replacing the initial EHF forming increments with one quasi-static preforming step. Additionally, a numerical model was developed and employed in order to better understand the sheet deformation process within EHF. The numerical model consists of four distinct models that are integrated into one: (1) an electrical model of the discharge channel, (2) a model of the plasma, (3) a model of the liquid as a pressure-transmitting medium, and (4) a deformable sheet metal blank in contact with a rigid die. Significant improvements in formability were confirmed experimentally for DP780 and DP980 by forming into conical and v-shape dies using EHF from a flat sheet and by using EHF combined with a quasi-static preforming step. Numerical modeling showed that the peak strain rates occurring in both single-pulse EHF the hybrid HF-EHF process are approximately 17,000 units per second.     

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.     

A Study of the Optimization of Sheet Metal Drawing with Active Drawbeads

An experimental study is described in which active drawbead technology is used to attempt to optimize the sheet metal forming process. Oval AA 6111-T4 panels were drawn in a series of tests using various drawbead trajectories to establish the feasibility of the approach. The selection of drawbead trajectory was shown to have a dramatic effect on maximum attainable draw depth at fracture. Increasing drawbead penetration from zero to 5 mm in the early stages of the drawing process and retracting midway through the draw resulted in a 40% increase in draw depth compared to using a fixed 5 mm penetration. In the second part of the investigation, active drawbead technology was used to study its effect on highly nonsymmetric panel forming. Drawing limit curves in terms of drawbead depth versus blankholder forces (BHF) were plotted, and different drawbead trajectories were tested to determine an optimal drawbead trajectory scheme. A corresponding finite element model was also created. The results of strain path analysis successfully support the experiments.     

薄板深拉延成形有限元仿真

板材成形有限元仿真采用虚拟制造技术反映模具与板材之间的相互作用以及板材实际变形的全过程,有助于推动生产的快速化和设计的智能化。汽车企业通过对板材成形过程的有限元仿真可确定钢板性能参数范围和冲压工艺参数范围,以保证生产的稳定性。采用动力显式有限元软件LS-DYNA,对上海宝钢St14-T冷轧薄板的深拉延成形过程进行了仿真计算,分析了变形过程的金属流动规律。     

多点成形--金属板材柔性成形的新技术

多点成形是一种板材三维曲面柔性成形的新技术.简述了多点成形的基本原理与系统构成并介绍了几种成形方式.在多点成形中,厚板曲面件可直接成形,薄板曲面件则采用柔性压边技术进行成形.利用多点成形技术的柔性特点还能实现分段成形、反复成形、多道成形以及闭环成形等新的板材成形工艺.