三维自由弯曲技术及变形区长度优化数值模拟研究

Three-dimensional Free-bending Technique and Numerical Simulation for Optimization of Deformation Zone Length

目的开展自由弯曲变形区长度优化研究,获得外径为15 mm、壁厚为2 mm的6061-T6铝合金管材的最优A值。方法从三维自由弯曲成形技术的基本原理及控制程序入手,基于有限元分析方法,利用ABAQUS仿真软件对管材三维自由弯曲成形过程进行数值模拟,研究成形过程中管材弯曲变形区的受力过程变化,分析变形区长度(A)对弯曲成形结果的影响规律。基于最优的变形区长度,对制冷系统管路中的6061-T6铝合金复杂空间弯曲构件进行仿真模拟及实际成形试验。结果试验成形构件尺寸与模拟成形构件尺寸相近且均接近设计尺寸,试验成形构件最大壁厚减薄率不超过9%,最大截面畸变率不超过5%,具有较好的成形质量。结论目标构件的有限元模拟及成形试验验证了变形区长度优化结果的准确性。

This paper aims to study optimum on length of free bending deformation zone to obtain the optimal A value of the 6061-T6 aluminum alloy tube with outer diameter of 15 mm and wall thickness of 2 mm. Based on basic principles and control programs of the three-dimensional free bending forming technology and finite element simulation, the basic forming process of three-dimensional free bending was simulated with the ABAQUS to study and analyze force change in the deformation zone of the tube during forming and effects of deformation zone length on bending results. Based on the optimal deformation zone length, complex bending members of 6061-T6 aluminum alloy in the refrigeration system piping were simulated and the actual forming tests were carried out. The size of the tested forming component was close to that of the simulated forming component and design size. The maximum wall thickness reduction rate of the test forming component was not more than 9%, the maximum section distortion rate was not more than 5%, and it had good forming quality. The finite element simulation and forming test of the target component verify the accuracy of the optimization result of the deformation zone length.