汽车轮辐错距强力旋压成形的有限元仿真

Finite Element Method Simulation of Stagger Power Spinning Forming of Automobile Spoke

利用ABAQUS软件建立轮辐三旋轮的错距强力旋压过程的弹塑性有限元仿真模型,并对成形过程进行分析;给出了仿真模型边界条件的施加方法和旋轮旋压轨迹曲线的加载方法;通过计算动能及伪应变能与内能的比率,并采用逆向扫描技术和实验测量方法对比分析仿真结果与轮辐生产件,以验证所建立模型的正确性.结果表明:与尾顶接触的材料不发生塑性变形,其他部位材料沿轮辐周向的塑性变形程度相当,而沿母线方向的塑性变形程度不同,并形成了等效塑性应变环和厚度环;在成形轮辐弯曲圆角处和外缘收口区域,材料的塑性变形程度较大,且材料堆积缺陷易出现在成形轮辐外缘收口区域;沿母线方向上不同位置处的轮辐的壁厚不同,壁厚变化遵循正弦规律.

In order to make an in-depth research on stagger spinning process of automobile spoke with three rollers, the elastic-plastic finite element simulation model was established and the forming process was analyzed based on ABAQUS. The methods for imposing boundary conditions and trajectory curves of rollers were introduced. The correctness of the simulation model was verified by calculating the ratios of kinetic energy and pseudo strain energy to internal energy and by comparing simulation results with production parts by using the reverse technique and experimental measurement. The results show that the material does not produce plastic deformation in the central area of the blank contacting with tailstock. Plastic deformation distributes homogeneously in the circumferential direction of the spoke and changes in the radial direction. Thus equivalent plastic strain rings and thickness rings are formed. Plastic deformation is severe when forming curved fillet areas and outer edge regions of the spoke. Material accumulation defect is likely to occur when forming outer edge regions of the spoke. The thickness of the spoke is different along the generatrix direction, and it changes in accordance with the sine law.