轮辋扩口成形过程的有限元分析

Finite Element Analysis on Expanding Forming Process for Wheel Rim

无内胎钢圈轮辋焊接接头开裂是轮辋成形过程的主要缺陷。基于ABAQUS软件,建立了轮辋扩口工序的三维弹塑性有限元仿真模型并对成形过程进行了分析。阐述了有限元模型中的单元选择、加载等关键问题。将仿真结果与轮辋的实际扫描模型进行外形尺寸比对,验证了建立模型的正确性。重点分析了扩口工序中工件的应力状态,提出环向拉应力过大是造成焊缝处开裂的原因和最大环向拉应力平均值的概念。模拟结果表明,随着摩擦系数或材料屈服强度的增大,工件最大环向拉应力平均值增大,工件焊接接头开裂倾向增大。

Welding joint cracking is the main defect in forming process of tubeless wheel rim. Three dimensional elastoplastic finite element simulation model of the expanding procedure for the wheel rim was established and the forming process was analyzed based on ABAQUS. The key questions such as unit selection in the finite element model and applying load were introduced. The correctness of the models was verified through comparing simulation results with the actual scanning model. The stress states of workpiece in expanding procedure were emphatically analyzed. It was proposed that the excessive circumferential tensile stress was the primary reason for cracking and concept of average value of the maximum circumferential tensile stress. Simulation results show that with the increase of the yield strength of materials or coefficient of friction, the average value of the maximum ring tensile stress of workpiece increases and the welding joint cracking tendency of workpiece increases.