大截面带内筋方箱辊拔成形数值模拟和实验研究

Numerical simulation and experimental study on roll drawing of large cross section square box with inner ribs

提出了一种大截面带内筋方箱辊拔整体成形工艺,利用有限元数值模拟软件对其成形过程、辊拔道次以及辊轮形状进行分析计算。对6061铝合金大截面带内筋方箱不同辊拔道次进行有限元模拟分析,发现三道次辊拔成形方案较一道次辊拔和二道次辊拔方案具有最好的成形效果:最低的损伤值以及几乎没有折叠缺陷,对应减薄系数压下变形方式形成的内筋最饱满,等效应变分布最均匀,并且具有最低的成形载荷。实验结果表明,6061铝合金大截面带内筋方箱的成形效果良好,内筋充填饱满。本文提出的大截面带内筋方箱整体成形技术,通过优化辊拔方案以及辊轮形状,方箱实际成形效果良好,可为生产实践提供理论指导。

Based on the drawing forming technology of metal materials,a new forming process of large section square box with inner ribs was proposed with considering the characteristics of profile forming technology such as roller press or rolling.The forming process,roller drawing passes and roller shape were studied by finite element numerical simulation.By analyzing the results of finite element simulation for different roll drawing passes,it is found that the three-pass roll drawing forming scheme gives the best forming result,e.g.,the lowest damage value and almost no folding defects.In addition,the fullest inner ribs formed by compression deformation corresponding to thinning coefficient,the most uniform of the equivalent strain distribution is and the lowest forming load it has.The physical experiments show that the forming effect of large cross-section box with internal ribs is good,and the internal ribs are fully filled.The new integral forming technology of large section square box with inner ribs was proposed.By optimizing the roll drawing scheme and roller shape,the actual forming effect of square box is good,which provides reference and theoretical guidance for production.