冷滚打成形中打入量对残余应力的影响规律仿真研究

BASED ON THE NUMERICAL SIMULATION OF COLD ROLL-BEATING FORMING RESIDUAL STRESS RESEARCH

在冷滚打成形过程中,当外加载荷逐渐卸去后成形件内部会出现残余应力,为了有效的控制其对成形件精度的影响,现针对打入量与残余应力之间的关系进行研究。依据冷滚打成形的基本原理,应用Abaqus软件建立了有限元动态仿真模型,通过仿真获得了不同打入量时工件表面Mises力的分布。由于动态仿真结果工件内部的力处于不平衡状态,不能直接进行残余应力求解,所以在动态仿真结果上建立了静态仿真模型,通过静态求解获得在不同打入量下成形工件在切向、轴向和径向的残余应力的变化规律。在自行开发的冷滚打设备上进行试验,运用X射线应力分析仪测量滚打后工件残余应力分布,进行冷滚打成形件残余应力的实验研究。通过对试件测量得到在不同打入量下制件沿深度方向的切向残余应力的分布,试验结果与有限元仿真结果对比分析表明,残余应力变化规律具有很好的一致性。

When the load to be lifted after cold roll-beating forming the residual stress will appear,in order to effectively control its impact on the forming precision,now the relationship between roll-beating depth and the residual stresses were studied.According to basic principle of cold roll-beating,a finite element dynamic simulation model is established by ABAQUS software,the distribution of Mises force on the workpiece surface was obtained by dynamic simulation at different roll-beating depth.Because inner force of workpiece in result of dynamic simulation is at unbalance state,it cannot directly solve the residual stress,so the static simulation model is established on result of dynamic simulation,and the roll-beating depth of different roll-beating of forming gullet section residual stress in tangential direction,axial direction and radial direction is determined by static analysis.Experiment on self-developed cold roll-beating equipment,build experimental platform for residual stress measurement,and study on residual stress of cold roll-beating.The distribution of the tangential residual stress along the depth direction is obtained by the measurement of the workpiece under different roll-beating depth,the comparison between the experimental results and the finite element simulation results shows that the residual stress variation has a good consistency,which verified effectiveness correctly of the simulation model.