基于缺陷控制的DP980高强钢三维变截面辊弯成形有限元仿真

Finite element analysis of 3D variable cross-section roll forming for DP980 high strength steel based on defect control

三维变截面辊弯成形时,辊组共轭空间曲线扫出空间曲面时仅能控制该曲线上的一点,存在非控制区,因此造成变截面辊弯过程中底部腹板具有"自由变形区",出现成形缺陷。基于双齿条单齿轮轴系结构的三维变截面辊弯成形装备,提出缺陷控制方法,并基于ABAQUS有限元仿真软件,建立缺陷优化仿真模型。针对DP980双相钢材料进行某汽车构件成形全流程有限元仿真,获得板材成形过程中复杂的变形规律、轧辊成形力与回弹预测。仿真结果表明,缺陷控制方法效果明显,成形件质量较好。通过成形实验进一步验证了缺陷控制的有效性,成形质量与仿真结果基本保持一致。

In the three dimensional variable cross-section roll forming, there exists non-controlled area because the roller group can only control one point on this curve when the conjugate space curve sweeps across space surface, which leading to ＂free deformation zone＂ at the bottom of plate in roll bending process, and then forming defects occure. Based on the three dimensional variable cross-section roll forming equipment with double rack single gear shaft structure, the defect control method was put forward, and the defect optimization simulation mode/was established based on ABAQUS. The whole process simulation of an automobile components forming with DP980 dual phase steel material was done so as to obtain the complex forming rules, roll forming force and springback prediction in sheet metal forming processes. The simulation results show that the effect of defect control method is obvious and the forming quality is better. Through forming experiment, the effectiveness of the defect control was further verified and the forming quality was consistent with the simulation results.