反转螺旋薄壁管件液压胀形的仿真与优化设计

Simulation and Optimal Design of Hydroforming of Reverse Spiral thin-wall Tube

反转螺旋薄壁管件是一种新开发的高效吸能的异型零件,由于形状比较特殊,加工过程中的厚度分布不均和过度减薄问题一直没有得到很好的解决。通过建立有限元分析模型,对管件液压成形的过程利用有限元分析软件LS-DYNA进行了模拟。利用响应曲面法进行优化得到液压胀形的最佳工艺参数,优化后的薄壁管件厚度分布更加均匀,减薄率在优化后降低了10.258%。最后通过比较优化前后的薄壁管件厚度和减薄率分布情况对优化结果进行了讨论和分析。

Reversal spiral thin-wall tube is a kind of newly developed special parts which can absorb energy efficiently. However, due to the special shape, the uneven distribution of thickness and excessive thinning problem are not solved well. Through establishing its finite element model, the hydroforming process of the thin-wall tube is implemented by finite element analysis soft ware LS-DYNA. Then, optimization problem is solved by response surface method and sequential quadratic programming method to achieve optimum process parameters of hydroforming. The thickness of tube is more homogeneous and the thinning reduced 10. 258% after optimization. Finally, by comparing the different thickness and thinning rate of the tube before and after optimization, the result of the optimization is analyzed.