B形防撞梁热辊弯成形过程仿真和试验研究

Simulation and experimental research on hot roll-bending forming process of B-shaped bumper

提出了一种适用于超高强度复杂截面管件类零件的热辊弯成形工艺。首先根据B形防撞梁热辊弯工艺过程建立了管件热辊弯多场耦合数值模拟整体流程,并采用ANSYS与ABAQUS/Explicit有限元仿真软件分别完成了电磁-热场耦合及热-力场耦合分析。在此基础上,根据感应加热温度场分布均匀性和成形后零件曲率半径要求,确定了感应线圈设计、弯曲进给速度及推弯速度等工艺参数。最后完成了实验装置开发和样件试制,并对样件截面显微硬度、金相以及零件弯曲曲率半径和整体尺寸精度进行了检测。结果表明:防撞梁热辊弯工艺样件截面典型位置抗拉强度大于1450 MPa,样件整体尺寸公差满足技术要求。

A hot roll-bending process suitable for pipe with ultra-high strength and complex section was proposed. Firstly,according to the hot roll-bending process of B-shaped bumper,the whole process of multi-field coupling numerical simulation of hot roll-bending of tube was established. The electromagnetic-thermal field coupling and thermal-force field coupling analysis were completed respectively using finite element simulation software ANSYS and ABAQUS/Explicit. On this basis,according to the distribution uniformity of the induction heating temperature field and the requirement of the curvature radius of the formed parts,the process parameters of induction coil design,bending feeding speed and pushing bending speed were determined. Finally,the development of experimental equipment and the trial-production of samples were completed,the microhardness and the microstructure of sample section,the radius of bending curvature and the overall dimension accuracy of the parts were tested. The results show that the tensile strength of the typical section of the bumper sample formed by hot roll-bending process is larger than 1450 MPa,and the overall dimensional tolerance of the sample meets the technical requirements.