基于虚拟弯曲理论的叠合型材冷弯成形

Investigation of roll forming for fold profile based on the theory of virtual bend

冷弯成形工件具有高效、经济的特点,发达国家每年冷弯成形工件的用量占钢铁用量的8%,而叠合型材是冷弯件中应用最多的一类,但由于存在回弹引起的质量问题,设计人员通常会以降低工件的其他性能以达到相似产品形状。该文基于型材叠合的虚拟弯曲理论,利用PROFIL冷弯轧辊计算机辅助设计软件及该软件自动建立ABAQUS模型的功能,分析冷弯成形过程。为验证虚拟弯曲理论的设计效果,分别建立了常见原始工艺路线和基于虚拟弯曲理论的叠合成形工艺路线,并利用有限元模拟,分析了两种板材叠合成形的工艺路线。受力分析结果和模拟结果均表明,叠合型材的补助弯曲设计可以解决叠合型材的回弹问题。

Nowadays about 8% of the annual consumption of steel is possessed by roll-formed parts for the characteristics of high efficiency and economic in developed countries.Fold profile part is the one of most widely used in roll-formed parts but the problem of springback still exist.The roll forming process was analyzed based on the theoretical analysis of the virtual bend for fold profile,and using the powerful computer-aided design software PROFIL with its function of automatically creating ABAQUS models.In order to verify the effect of designing with virtual bend theory,the common process which generate springback and the advanced process based on the principle of virtual bend were designed.Two different processes by finite element analysis with ABQAUS were analyzed.The results of force analysis and simulation both demonstrate that the virtual bend design is a clever way to solve the springback of fold profile.