Numerical simulation on the process of multi-point forming for tube

To apply the multi-point forming technology to the field of tube processing,the process of multi-point forming for tube is studied.Numerical simulation for the process of multi-point forming for tube is achieved by using elastic-plastic FEM in ABAQUS.During simulation,reasonable coefficient of mass scaling and friction model of penalty function are used.The influence of several major technological parameters on the process is analyzed.When the tube diameter is 60 mm and the forming curvature radius is 1000 mm,the distortion rate of cross-section and the absolute forming error gradually decrease with the increasing of tube wall thickness;However,when the tube wall thickness is constant,the smaller the curvature radius,the larger the distortion rate of cross-section,but as to forming part,its absolute forming error becomes smaller.

Simulation on damage effectiveness of hexagonal prism aimable warhead with multi-point synchronous initiations

In order to study the impacts of warhead geometry and initiation pattern on the lethality of aimable warhead, multi-point synchronous initiated hexagonal prism and cylindrical warheads were compared through numerical simulation, combined with theoretical formulas of fragment decelera- tion and target plugging. Enhancements of fragment velocity, kinetic energy and density toward the target and target destructions were analyzed. The results show that hexagonal prism warhead can produce dense fragment beams and enhance average velocity and kinetic energy with asymmetric eight-point initiation by 24. 13% and 54. 52% respectively, which are higher than those of the isomet- ric or same weight cylindrical warhead. The effective fragments are still relatively concentrated in an area of 8 m × 2 m for the hexagonal prism warhead when the distance between warhead and target is 40 m.

Improving effect on forming quality and accuracy using a polyurethane board positioning/resetting the discrete steel pad in multi-point forming

To improve the quality of multi-point die forming, a new approach using discrete steel pads was proposed. The formability of three different multi-point die forming processes was analyzed through numerical simulation and experiments. Numerical simulation and experimental results showed that the use of discrete steel pads in the multi-point forming process can substantially improve the stress–strain state on the plate and suppress dimple, straight-edge, and wrinkle defects. This analysis verified that the use of discrete steel pads in a multi-point forming process can effectively improve the quality and accuracy with which sheet metal is formed.

Numerical Modelling of Ore-forming Dynamics of Fractal Dispersive Fluid Systems

Based on an analysis of the fractal structures and mass transport mechanism of typical shear-fluid-ore formation system, the fractal dispersion theory of the fluid system was used in the dynamic study of the ore formation system. The model of point-source diffusive illuviation of the shear-fluid-ore formation system was constructed, and the numerical simulation of dynamics of the ore formation system was finished. The result shows that: (1) The metallogenic system have nested fractal structure. Different fractal dimension values in different systems show unbalance and inhomogeneity of ore-forming processes in the geohistory. It is an important parameter to symbolize the process of remobilization and accumulation of ore-forming materials. Also it can indicate the dynamics of the metallogenic system quantitatively to some extent. (2) In essence, the fractal dispersive ore-forming dynamics is a combination of multi-processes dominated by fluid dynamics and supplemented by molecule dispersion in fluids and fluid-rock interaction. It changes components and physico-chemical properties of primary rocks and fluids, favouring deposition and mineralization of ore-forming materials. (3) Gold ore-forming processes in different types of shear zones are quite different. (1) In a metallogenic system with inhomogeneous volumetric change and inhomogeneous shear, mineralization occurs in structural barriers in the centre of a shear zone and in geochemical barriers in the shear zone near its boundaries. But there is little possibility of mineralization out of the shear zone. (2) As to a metallogenic system with inhomogeneous volumetric change and simple shear, mineralization may occur only in structural barriers near the centre of the shear zone. (3) In a metallogenic system with homogeneous volumetric change and inhomogeneous shear, mineralization may occur in geochemical barriers both within and out of the shear zone.

Geodynamic simulation of the WenChuan Ms8.0 and Lushan Ms7.0 earthquakes

The Lushan Ms7.0 earthquake, occurred on April 20th, 2013, is another strong earthquake that occurred on Longmen Mountain Faults after the Wenchuan Ms8.0 earthquake. In this paper we construct a finite element model depicting fault frictional mechanism to study the geodynamics of these two strong earthquakes. The locations of the initial rupture points and the dislocation forms of the Wenchuan earthquake and Lushan earthquake are simulated to find out the potential relationship between the two earthquakes. Simulative results show that the elevation, fault geometry, and the different rheological strengths between the Sichuan basin and Tibetan plateau play an important role in the earthquake dynamics. The dynamic simulation shows the initial rupture points are located at Yingxiu county and the rupture process is mainly along the northeast direction for the Wenchuan earthquake. In particular, the different frictional strengths caused by the fluid pressure decrease between the southern and northern segments of Longmenshan faults after the Wenchuan earthquake have affected the initial rupture point and the fault dislocation form of the Lushan earthquake, when considering the thrust of Tibetan plateau to Sichuan basin as the major dynamic source.

Influence of a multi-step process on the thickness reduction error of sheet metal in a flexible rolling process

Flexible rolling is a forming process based on thickness reduction, and the precision of thickness reduction is the key factor affecting bending deformation. The major purpose of the present work is to solve the problem of bending deformation error caused by insufficient thickness reduction. Under the condition of different rolling reductions with the same sheet thickness and the same thickness reduction with different sheet thicknesses, the thickness reduction error of sheet metal is analyzed. In addition, the bending deformation of sheet metal under the same conditions is discussed and the influence of the multi-step forming process on the thickness reduction error is studied. The results show that, under the condition of the same sheet thickness, the thickness reduction error increases with increasing rolling reduction because of an increase in work hardening. As rolling reduction increases, the longitudinal bending deformation decreases because of the decrease of the maximum thickness difference. Under the condition with the same thickness reduction, the thickness reduction error increases because of the decrease of the rolling force with increasing sheet thickness. As the sheet thickness increases, the longitudinal bending deformation increases because of the increase in the maximum thickness difference. A larger bending deformation is divided into a number of small bending deformations in a multi-step forming process, avoiding a sharp increase in the degree of work hardening; the thickness reduction error is effectively reduced in the multi-step forming process. Numerical simulation results agree with the results of the forming experiments.

工艺参数对AZ31B镁合金单点渐进翻边精度的影响

目的以AZ31B镁合金板为研究对象,研究初始成形角、工具直径、成形温度及层间距对单点渐进圆孔翻边精度的影响规律。方法使用有限元软件对2 mm厚的镁合金板材进行数值模拟,通过计算翻边直壁处的平均回弹量,得出不同工艺参数对单点渐进圆孔翻边直壁轮廓的影响规律。通过正交实验分析了交互作用下工艺参数对圆孔翻边直壁处平均回弹量的影响,通过极差分析确定了最优工艺参数组合,并通过实验对所得结果进行了验证。结果随着初始成形角的增大、工具直径的增大、成形温度的升高及层间距的减小,圆孔翻边制件直壁处的成形精度提高,各因素按影响程度由大到小的顺序依次为:成形温度、初始成形角、工具直径和层间距。成形精度最高的工艺参数组合如下:初始成形角为30°、工具直径为10 mm、成形温度为275℃、层间距为0.5 mm。结论采用仿真模型模拟单点渐进圆孔翻边过程具有较高的准确性,使用优化后的工艺参数得到翻边零件直壁区域的最小厚度以及平均回弹量与仿真结果误差均在3%以内,升高温度可以明显提高单点渐进圆孔翻边的制件精度。

海底管线管全流程成形过程中残余应力演化

为了研究海底管线管全流程成形过程中残余应力的演化,考虑成形工序中应力的继承,采用ABAQUS软件开展了管线管JCO、焊接和多向缩径校准全流程成形过程有限元模拟。首先进行了JCO成形过程模拟,然后基于高斯面热源子程序对JCO成形后的管线管进行了焊接过程模拟,最后对焊接后的管线管进行了多向缩径校准成形过程模拟,探讨了多向缩径校准成形工艺参数对管线管残余应力的影响。模拟结果表明:多向缩径校准可以实现管线管几何形状和残余应力的双重调控;相对传统的2瓣模具缩径,采用4瓣模具和8瓣模具校准后的管线管残余应力分布更加均匀;摩擦因数对残余应力的影响不明显;采用4瓣模具、 0.04摩擦因数和1.6%缩径率校准后的管线管椭圆度可达0.05%,除焊接热影响区,管线管内外表面的最大周向残余应力分别为28和-45 MPa,截面Mises残余应力均值为(120±20) MPa,焊缝区和非焊缝区的Mises残余应力均值分别降低了79%和30%。

轴向预制破片战斗部飞散特性数值模拟

为分析轴向预制破片战斗部的飞散特性,利用LS-DYNA软件模拟轴向预制破片战斗部中心单点起爆方式和多点起爆方式下破片速度及飞散角特征参数并进行试验验证,得到了中心单点起爆和多点起爆方式对破片速度及飞散角特征参数的影响规律。研究表明:相较于中心单点起爆方式,多点起爆方式可以提升轴向预制破片速度,且随着起爆点数增加,破片速度先增加后趋于稳定,起爆点数从2点增加到6点,破片初速提升了21.1%,当起爆点数继续增加,则破片速度不再增益,而起爆点数对飞散角影响较小。

铝合金板料成形间距对逐点连续电磁成形过程的影响规律

电磁成形具有高速成形和提高材料塑性成形性能的特点,非常适用于准静态下难加工轻质铝合金材料的成形。在电磁系统中加入集磁器可以实现对工件的局部加工,但当电磁集中在小区域内多次成形时,由于两个成形点的距离较小,存在局部变形相互影响的区域,从而影响板料成形的均匀性。为研究逐点连续电磁成形过程中局部变形之间的相互作用机理,采用数值模拟结合实验验证的方法,探究了金属板料小区域逐点连续电磁成形过程中的变形行为,揭示了成形间距对板料成形涉及的电磁力、应变和最终成形效果的影响规律。研究结果表明,在单次电磁成形时,板料受到的电磁力呈环状分布,成形点中心受到径向与切向压应变和轴向拉应变,成形点四周受到径向拉应变和轴向与切向的压应变。在多次成形时,随着两成形点间距减小,板料在第二次成形时受到变形区的影响,影响间距为14 mm,板料中心所受的径向压应变和轴向拉应变增大,板料电磁力逐渐增大。第二成形点中心的成形高度随着两成形点间距的增加逐渐增加,两个成形点衔接处的凹槽深度也越深,而两个成形点衔接处的径向拉应变随着成形间距的增加表现为先增大后减小的趋势。本研究为在铝合金板料多点电磁成形过程中两点变形间距对电磁力和成形效果的影响提供了理论依据。

大型厚板曲面件的多点成形仿真

传统的厚板曲面件制造方法存在着成本高、效率低等问题,多点成形技术为这一问题提供了解决方法。但多点成形技术又因为回弹导致工艺参数难以确定使实验操作次数增加,降低成形效率。为了提高成形效率,采用ABAQUS有限元软件模拟与实验相结合的方法进行板料成形的研究与分析。首先,利用有限元软件进行三维建模并模拟板料的成形过程;然后,通过对模拟结果的分析进行模具型面的补偿修正;最后,利用修正后的模具型面进行实验操作,获得了符合要求的零件。对修正后的型面进行成形实验可以减少操作次数,提高实验的成形效率,为后续的研究提供参考。

1×××/7×××系铝合金液-固铸轧复合模拟研究

结合双辊立式铸轧机设备和技术参数,通过流-固耦合的方法进行了变参数正交模拟研究,揭示了1×××系铝液浇铸温度和铸轧速度对铸轧复合区内温度场、流场的影响。研究结果表明,最优铸轧参数区间为浇铸温度670~690℃、铸轧速度12~13 m/min。浇铸温度越高、铸轧速度越快越容易发生漏液,反之容易发生轧卡。

多点荷载作用下钢筋混凝土梁受力特性及损伤演化规律研究

钢筋混凝土结构因其具有较好受拉和抗压性能,在各种建筑领域中被广泛使用。钢筋混凝土结构作为现代建筑工程中广泛采用的一种关键结构形式,其在服役期间的损伤特性一直是工程领域关注的重点。该文利用ABAQUS有限元数值软件,建立多点荷载作用下钢筋混凝土梁的数值仿真计算模型,对钢筋混凝土梁的多点荷载作用下受力特性及损伤演化规律开展研究。研究发现,钢筋混凝土梁在竖向位移荷载作用过程中,拉应力集中于梁下部,压应力区在梁上部;随外部荷载持续作用,纵向受力钢筋上形成的应力会传递至环向的箍筋上;钢筋混凝土梁在纯弯段受压区处,混凝土的应变大于材料的最大压缩应变,导致受压区内的混凝土出现损伤破坏;在钢筋混凝土梁受力过程中,混凝土的强度等级和受拉钢筋的强度等级对梁体的整体强度有决定性作用。

一种厚板多点成形工艺仿真辅助建模程序开发与验证

为提高厚板多点成形工艺仿真建模效率,基于ANSA的Python API接口程序,开发了一种厚板多点成形仿真辅助建模程序。该辅助建模程序包含模型准备和模型创建两大模块。模型准备模块用于压头快速定位,形成目标成形面以及实现压头和工件初始接触。模型创建模块用于边界条件定义以及仿真分析参数设置。使用该辅助建模程序建立了一系列不同曲率半径的球面件多点成形仿真模型,并进行了成形和回弹计算。实验结果对比分析表明:该程序能够在同一软件环境下快速建立复杂型面的多点成形仿真模型。回弹计算结果与实验结果趋势一致,曲率半径越大,结果误差越大。仿真辅助建模程序提高了建模的效率,缩短了分析周期。

高强度钢板热冲压材料性能研究及在车身设计中的应用

对热成形零部件的材料性能进行拉伸测试及金相试验研究,板料经过热成形后零部件的屈服强度超过1 000 MPa,抗拉强度达到1 600 MPa。对热成形门内加强梁进行3点弯曲试验并同时进行耐冲击数值模拟,说明热成形零部件具有优异的承载能力及耐碰撞冲击性能,适用于车身耐冲击构件的选材。提出高强度钢板热成形零部件用于车身设计的'功能设计'方法。设计热冲压零部件用于车身设计的三种方案,并进行整车的侧面碰撞数值仿真结果比较,阐明高强度钢板热成形构件对于提高整车耐冲击性能的作用机理:热成形零部件用于车身设计时应进行整体骨架布局,形成驾驶员及乘客的超高强度保护仓;避免简单应用单个高强度热成形零部件,防止冲击时侵入车体。总结热成形零部件用于车身的'功能设计'方法。

多点成形时工艺方式与工件压痕的关系研究

多点成形是一种先进的制造技术,但其成形特点与传统的冲压成形方式相比具有很大差别.本文采用有限元数值模拟手段针对多点成形过程中产生的压痕现象以及消除压痕的措施进行探讨,主要是对比多点模具成形和多点压机成形两种不同工艺,分析不同成形工艺条件下对压痕的影响.本文用显式动力学软件对1mm与3mm厚度的马鞍型曲面件进行数值模拟,结果表明,在相同条件下,用多点模具工艺成形的板材比用多点压机工艺成形的板材压痕深度大3-15倍,而且在成形过程中出现压痕的时间早.多点压机成形方式比多点模具成形方式具有成形效果好,缺陷少(可以减小或消除压痕和起皱等缺陷),并且有利于板材的流动,能够得到更大的变形量.

板材多点成形技术研究综述

多点成形是一种先进的板材成形技术 ,吉林大学无模成形技术开发中心进行了大量的研究工作。本文介绍了该中心在板材多点成形设备。

多点拉形数值模拟及模具型面补偿方法

建立了板料多点拉形有限元模型,确立了用于动态显式算法的拉形加载模式,并应用到典型件的拉形过程数值模拟中。对马鞍形曲面件的多点拉形进行了数值模拟,探讨了成形件上应力、厚度等的分布规律以及回弹和弹性垫的不均匀变形对成形件精度的影响。模拟结果表明,成形件的应力、厚度分布均匀,卸载回弹很小,弹性垫的不均匀变形对成形件精度的影响比回弹要大;为获得精确形状的成形件,提出了一种基于数值模拟结果通过反复修正获得准确的多点拉形模具型面来补偿多点拉形中弹性垫的不均匀变形和回弹的方法。

金属板材多点柔性成形理论与应用

多点柔性成形是一种先进的金属板材成形技术 ,这种成形方法能够实现成形路径选择、分段成形等传统成形方法无法实现的功能 .文中基于理想路径成形理论 ,提出了板材多点柔性成形最优成形路径设计的理论与方法 ,建立了多点分段成形过渡区设计准则与多点成形过程中静力隐式弹塑性大变形有限元数值模拟方法 .应用给出的路径设计理论与方法 ,计算了典型样件的最优成形路径 ,应用数值模拟理论、方法及开发的数值模拟软件进行了典型件多点成形过程的数值模拟 .

板材多点成形过程数值模拟的研究

多点柔性成形是一种先进的板材成形技术。在多点成形过程中 ,板材的受力状态、变形特点、接触边界等与传统的冲压成形有很大的不同 ,商业软件不能有效地反应这些特点。本文给出了自主开发的板材多点成形过程数值模拟专用软件 (MPFORM)所采用的有关理论与公式 ,介绍了基于UL隐式格式的弹塑性大变形有限元方法、退化板壳有限元模型以及处理多点不连续接触边界的接触单元技术等 。