金属板料单点渐进成形性能研究
发布时间：2018-08-30 13:14
【摘要】：金属板料单点渐进成形技术是一种新型的柔性无模成形技术,适合于多品种、小批量产品的新品种研发与制造,对于汽车、航空航天、家用电器、医疗器械等领域具有十分广阔的应用前景。在渐进成形实际生产中,许多工艺参数的选择影响着成形件的质量,解决渐进成形缺陷还需要对渐进成形机理做进一步深入研究。本文基于ANSYS/LS-DYNA有限元软件,建立起适合板料单点渐进成形的数值模拟分析模型,通过渐进成形截头锥形件分析单点渐进成形机理,并且数值模拟与试验综合探究工艺参数对板料的单点渐进成形性能的影响规律。主要的工作内容如下：1)在Matlab环境下编程运行GUI程序成功解决了复杂成形轨迹加载的难题,实现了对单点渐进成形完整的模拟过程。2)从应力状态、应变状态以及厚度分布几个方面分析了单点渐进成形机理,结论显示：①正在成形区的所有单元属于三向应力状态,两拉一压；②应变状态与成形区域和成形路径有关。圆形路径加载时,微小变形区为压缩类变形,过渡变形区为压缩类变形和剪切类变形的混合,均匀变形区和正在变形区为纯剪切类变形；直线路径加载时,所有的变形区均为压缩类变形；③单点渐进成形件的厚度分布余弦定理只适用于过渡变形区后半段、均匀变形区和正在变形区。3)数值模拟与试验验证研究了原始板厚、垂直增量步长以及零件形状对金属板料单点渐进成形性能的影响规律,并试验探究渐进成形过程中润滑剂的选择。结果显示：由于成形工具头与板料的磨损,薄板的变形区厚度就相对于厚板变得更薄：垂直增量步长太小或者太大都不利于渐进成形,太小不会引起温度效应使金属发生回复与再结晶,太大导致变形的不均匀倾向和摩擦力的增大；相比圆锥台,方锥台的平均应变量更小,变形更均匀,厚度减薄情况也得到了改善；采用极压添加剂的润滑脂作为渐进成形的润滑剂,耐压性高,粘附性好,润滑效果理想。
[Abstract]:Single point incremental forming of sheet metal is a new type of flexible die forming technology, which is suitable for the research and manufacture of many kinds and small quantities of products, such as automobile, aerospace, household appliances, etc. Medical devices and other fields have a very broad application prospects. In the practical production of incremental forming, the selection of many process parameters affects the quality of forming parts. To solve the defects of incremental forming, it is necessary to further study the mechanism of incremental forming. Based on ANSYS/LS-DYNA finite element software, a numerical simulation analysis model suitable for sheet metal single point progressive forming is established in this paper. The influence of process parameters on single point incremental forming performance of sheet metal was investigated by numerical simulation and test. The main work is as follows: (1) programming and running GUI program under Matlab environment successfully solves the difficult problem of complex forming trajectory loading, and realizes the complete simulation process of single point progressive forming process .2) from stress state. The mechanism of single point progressive forming is analyzed in terms of strain state and thickness distribution. It is concluded that all the elements in the forming zone of 1 / 1 are in a three direction stress state, and the strain state of two drawing and pressing is related to the forming region and forming path. When the circular path is loaded, the small deformation zone is compression-like deformation, the transition deformation zone is a mixture of compression-like deformation and shear-like deformation, and the uniform deformation zone and the current deformation zone are pure shear-like deformation. The thickness distribution cosine theorem of all the deformation regions is compression-like deformation-3 single-point progressive forming parts. The CoSine theorem is only applicable to the second half of the transition deformation zone, the uniform deformation zone and the in-process deformation zone .3) numerical simulation and experimental results show that the original plate thickness is studied. The influence of vertical incremental step size and part shape on sheet metal single point progressive forming performance was studied. The selection of lubricant in incremental forming process was investigated. The results show that due to the wear of the forming tool head and sheet metal, the thickness of the deformation zone of the sheet becomes thinner than that of the thick plate, and the vertical incremental step is too small or too large to be conducive to progressive forming. Too small does not cause temperature effect to cause recovery and recrystallization of the metal, and too much leads to the uneven tendency of deformation and the increase of friction; compared with the cone table, the average strain of the square cone is smaller and the deformation is more uniform. The thickness thinning is also improved, and the lubricating grease with extreme pressure additive is used as the lubricant of progressive forming, which has high pressure resistance, good adhesion and ideal lubricating effect.
【学位授予单位】：合肥工业大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TG306
[Abstract]:Single point incremental forming of sheet metal is a new type of flexible die forming technology, which is suitable for the research and manufacture of many kinds and small quantities of products, such as automobile, aerospace, household appliances, etc. Medical devices and other fields have a very broad application prospects. In the practical production of incremental forming, the selection of many process parameters affects the quality of forming parts. To solve the defects of incremental forming, it is necessary to further study the mechanism of incremental forming. Based on ANSYS/LS-DYNA finite element software, a numerical simulation analysis model suitable for sheet metal single point progressive forming is established in this paper. The influence of process parameters on single point incremental forming performance of sheet metal was investigated by numerical simulation and test. The main work is as follows: (1) programming and running GUI program under Matlab environment successfully solves the difficult problem of complex forming trajectory loading, and realizes the complete simulation process of single point progressive forming process .2) from stress state. The mechanism of single point progressive forming is analyzed in terms of strain state and thickness distribution. It is concluded that all the elements in the forming zone of 1 / 1 are in a three direction stress state, and the strain state of two drawing and pressing is related to the forming region and forming path. When the circular path is loaded, the small deformation zone is compression-like deformation, the transition deformation zone is a mixture of compression-like deformation and shear-like deformation, and the uniform deformation zone and the current deformation zone are pure shear-like deformation. The thickness distribution cosine theorem of all the deformation regions is compression-like deformation-3 single-point progressive forming parts. The CoSine theorem is only applicable to the second half of the transition deformation zone, the uniform deformation zone and the in-process deformation zone .3) numerical simulation and experimental results show that the original plate thickness is studied. The influence of vertical incremental step size and part shape on sheet metal single point progressive forming performance was studied. The selection of lubricant in incremental forming process was investigated. The results show that due to the wear of the forming tool head and sheet metal, the thickness of the deformation zone of the sheet becomes thinner than that of the thick plate, and the vertical incremental step is too small or too large to be conducive to progressive forming. Too small does not cause temperature effect to cause recovery and recrystallization of the metal, and too much leads to the uneven tendency of deformation and the increase of friction; compared with the cone table, the average strain of the square cone is smaller and the deformation is more uniform. The thickness thinning is also improved, and the lubricating grease with extreme pressure additive is used as the lubricant of progressive forming, which has high pressure resistance, good adhesion and ideal lubricating effect.
【学位授予单位】：合肥工业大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TG306
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