连续辊压成形中的起皱缺陷分析

Analysis on the wrinkling in continuous roll forming

三维曲面连续辊压成形技术是一种新型的板材成形技术,通过一对可弯曲辊及其形成的辊缝即可实现双向曲率的板料成形。利用数值模拟方法对连续辊压过程中板材的最大压缩率和板材厚度对起皱缺陷的影响进行了研究。研究结果表明,当最大压缩率过大时,凸曲面件中间部位与鞍形件边缘易产生起皱缺陷,起皱程度随最大压缩率增加而增大。增大板材厚度,对失稳起皱具有抑制作用。对数值模拟结果进行实验验证,利用PRO CMM光学追踪器对实验件进行三维型面测量分析,实验结果证明了模拟结果的正确性。

3D continuous roll forming is a new type of sheet metal forming technology. A double curvature part can be formed by a pair of bendable rolls and formed roll gap. The influence of the maximum compression ratio and the thickness of the sheet on the wrinkling defects were studied by numerical simulation method. The results show that when the maximum compression ratio is too large,wrinkling appears on the edges of the saddle surface parts and central area for the convex surface parts. Furthermore,the wrinkling degree increases with the increase of the maximum compression ratio. Increasing thickness of the plate can reduce the degree of wrinkling. Experiments were conducted to verify the numerical simulation results,and the wrinkling degree of experimental parts were measured and analyzed by PRO CMM optical tracker equipment. The experimental results show the validity of the simulation results.