大截面Z型材数控滚弯成形精度的数值模拟研究

Finite Element Analysis of Forming Accuracy in Roll-bending Process for Large Cross-section Z Profile

为了提高型材滚弯成形外形轮廓的精度,研究了Z型材滚弯成形回弹变形规律,建立了型材成形半径与滚弯机侧滚轮位移的关系,给出了考虑回弹变形的型材滚弯成形工艺参数。基于ABAQUS有限元软件,建立了型材滚弯成形过程的三维模型,分析了主滚轮尺寸、夹紧力和摩擦系数对型材沿长度方向各段曲率变化的影响。结果表明:主滚轮尺寸越大,曲率分布越均匀;并确定出该型材滚弯成形时合理的夹紧力和摩擦系数范围。应用模拟分析确定的最佳工艺参数完成该型材的滚弯成形加工,验证了该参数对滚弯型材外形精度的提高作用。

To improve the shape accuracy of profile in the roll-bending,the springback law Z shaped profile in rollbending is experimentally investigated,the relation between the forming radius of profile and displacement of the side roll is established and the forming parameters for roll-bending is obtained with considering the springback. A3 D model for the roll-bending forming is proposed,and ABAQUS software is employed to analyze the influence of the main roller size,clamp force and friction coefficient on the curvature radius of each section in the longitude direction. The results show that the bigger main roller size is,the better the uniform distributed curvature. The reasonable clamp force and the range of friction coefficient of this Z shaped profile were given in this paper. With adopting these optiumu parameters obtained with FE simulation,the roll-bending experiments were carried out,and the the shape accuracy for final formed profile was improved.