一种新辊型的增量滚压成形过程仿真

Simulation of incremental rolling process for a new roller profile

增量滚压成形工艺采用渐进成形的方式在板材表面滚压微沟槽结构,在该工艺原理的基础上,将传统的单一辊型设计为4种不同的辊型。采用有限元软件对新辊型的增量滚压成形过程进行数值模拟,与传统辊型的成形效果进行对比,并分析了新辊型滚压时工件材料流动的特点。结果表明:滚压完成后,新辊型与传统辊型成形的微沟槽高度相等,但后者成形工件端部的堆积量小于前者;在此成形过程中,采用新辊型的辊轮承受的成形载荷更小;通过对工件的速度场、应力场以及应变场的分析,得到工件材料在成形过程中的流动特点,为今后辊轮的优化设计提供了有效的参考。

Incremental rolling technology is a process of rolling micro-groove structure on sheet metal surface by incremental forming.Based on the principle of the process,the traditional single roller profile was designed into four kinds of roller profile,and the incremental rolling process of the new roller profile was simulated by finite element software.Then,the forming quality of the new roller profile was compared with that of the traditional roller profile,and the material flow characteristics of workpiece during the rolling process of the new roller profile were analyzed.The results show that the micro-groove height of the new roller profile is equal to that of the traditional roller profile after rolling,but the accumulation at the end of workpiece formed by the latter is less than that of the former.However,the forming load of the new roller profile is smaller.Furthermore,the flow characteristics of workpiece material during the forming process are obtained by the analysis of the velocity field,equivalent stress field and strain field of workpiece,which provides an effective reference for the optimization design of roller in the future.