大型U形板材工件渐进滚弯成形数值模拟

Numerical simulation of multiple-step incremental roll-bending forming of large-scale sheet metal with U shape

利用ABAQUS有限元分析平台,对大型U形板材工件渐进滚弯成形及其回弹过程进行数值模拟,其中工件材料类型选择普通低碳钢。针对半椭圆形工件形状,提出用半径不同的五段圆弧逼近的几何规划。在此基础上,根据加工过程可能出现的缺陷,合理设计滚弯道次,调整ABAQUS参数设置。用模拟优化的工艺参数成形加工半椭圆形板材工件,经origin8拟合配准,其各段曲率半径最大误差小于5%。模拟结果表明,用渐进滚弯方法成形加工半椭圆形工件是可行的,且模拟过程满足准静态响应的要求。

Simulation of multiple-step incremental roll-bending forming and spring back of large-scale sheet metal with U shape was implemented in this paper using ABAQUS,in which the low-carbon steel is selected as the material type.In view of the semi-ellipse shape of workpiece,a geometric plan using fives arcs with different radius to approach the original shape in piecewise is proposed.On the basis of the programming and according to the possible defects in the processing,the rolling steps are reasonably arranged,and the parameters are adjusted in ABAQUS.The largest error of curvature radius of different arcs is less than 5% after simulation of the sheet metal forming according to optimized process fitting with origin8.The results show that the incremental roll-bending method for forming the semi-ellipse shape workpiece is feasible and the simulation process meets the requirements of the quasi-static response.