Currently requirements of thin-walled tube with small bending radius cause the defects such as wrinkling, overthinning and cross-section distortion more prone to occur in bending process. Based on the analysis of the ...Currently requirements of thin-walled tube with small bending radius cause the defects such as wrinkling, overthinning and cross-section distortion more prone to occur in bending process. Based on the analysis of the forming characteristics by analytical and experimental methods, a complete 3D elastic-plastic FEM model of the process was developed using ABAQUS/Explicit code, including bending process, balls retracting and unloading process, and thus the plastic deformation characteristics with small bending radius were investigated. The main results show that: 1) The utmost deformation feature of the NC bending process is its continuous progressive deformation. 2) The occurring conditions of the defects such as wrinkling and tension instability in the process are obtained. The wrinkling is traditional on the double compressive stresses state and the tension instability is on the double tension stresses state. 3) The enhanced non-uniform deformation in thin-walled tube with small bending radius is demonstrated by comparing the stress/ strains distributions under the 1.5D and 1D bending conditions. 4) For ID small bending process, a new method-'stepped mandrel retraction' is proposed to improve the bending quality in experiment according to the FE simulation. The simulation results are verified by experiment.展开更多
Electromagnetic V-shape bending of small size sheet blank is investigated numerically and experimentally. Three-dimensional electromagnetic field models are established to calculate the magnetic force distribution on ...Electromagnetic V-shape bending of small size sheet blank is investigated numerically and experimentally. Three-dimensional electromagnetic field models are established to calculate the magnetic force distribution on the sheet by software ANSYS / EMAG. Series of electromagnetic V-shape bending forming experiments are presented,in which small size uniform pressure coil and big size round flat spiral coil are used. The results show that small size uniform pressure coil is not suitable for electromagnetic forming of small size flat sheet,and the coil is susceptible to failure such as bulging,ablation and cracking. When the plane dimension of round flat spiral coil is bigger than sheet blank sizes,the induced current crowding effect will be resulted which seriously influence the magnetic force distribution on the sheet. In this case,magnetic force distribution can be adjusted through the change of the relative position between coil and sheet,the desired deformation can be obtained finally. Therefore,big size round flat spiral coil can be well applied to electromagnetic V-shape bending forming of small size flat sheet.展开更多
The forming limit curve （FLC） can be obtained by means of curve fitting the limit strain points of different strain paths. The theory of percent regression analysis is applied to the curve fitting of forming limit e...The forming limit curve （FLC） can be obtained by means of curve fitting the limit strain points of different strain paths. The theory of percent regression analysis is applied to the curve fitting of forming limit experimental data.Forecast intervals of FLC percentiles can be calculated. Thus reliability and confidence level can be considered. The theoretical method to get the limits of limit strain points distributing region is presented, and the FLC position can be adjusted according to practical requirement. Method for establishing FLC with high reliability using small samples is presented at the same time. This method can make full use of the current experimental data and the previous data.Compared with the traditional method that can only use current experimental data, fewer specimens are required in the present method to obtain the same precision and the result is more accurate with the same number of specimens.展开更多
基金Projects(59975076, 50175092) supported by the National Natural Science Foundation of China Project(50225518) by the National Science Found of China for Distinguished Young Scholars Project by the Teaching and Research Award Program for Outstanding Young Teachers in Higher Education Institutions of MOE, PRC Project(20020699002) by the Specialized Research Fund for the Doctoral Program of Higher Education of MOE, PRC Project (04H53057) by Aviation Science Foundation
文摘Currently requirements of thin-walled tube with small bending radius cause the defects such as wrinkling, overthinning and cross-section distortion more prone to occur in bending process. Based on the analysis of the forming characteristics by analytical and experimental methods, a complete 3D elastic-plastic FEM model of the process was developed using ABAQUS/Explicit code, including bending process, balls retracting and unloading process, and thus the plastic deformation characteristics with small bending radius were investigated. The main results show that: 1) The utmost deformation feature of the NC bending process is its continuous progressive deformation. 2) The occurring conditions of the defects such as wrinkling and tension instability in the process are obtained. The wrinkling is traditional on the double compressive stresses state and the tension instability is on the double tension stresses state. 3) The enhanced non-uniform deformation in thin-walled tube with small bending radius is demonstrated by comparing the stress/ strains distributions under the 1.5D and 1D bending conditions. 4) For ID small bending process, a new method-'stepped mandrel retraction' is proposed to improve the bending quality in experiment according to the FE simulation. The simulation results are verified by experiment.
基金Sponsored by the National Basic Research Program of China(Grant No.2011CB012800 and 2011CB012804)
文摘Electromagnetic V-shape bending of small size sheet blank is investigated numerically and experimentally. Three-dimensional electromagnetic field models are established to calculate the magnetic force distribution on the sheet by software ANSYS / EMAG. Series of electromagnetic V-shape bending forming experiments are presented,in which small size uniform pressure coil and big size round flat spiral coil are used. The results show that small size uniform pressure coil is not suitable for electromagnetic forming of small size flat sheet,and the coil is susceptible to failure such as bulging,ablation and cracking. When the plane dimension of round flat spiral coil is bigger than sheet blank sizes,the induced current crowding effect will be resulted which seriously influence the magnetic force distribution on the sheet. In this case,magnetic force distribution can be adjusted through the change of the relative position between coil and sheet,the desired deformation can be obtained finally. Therefore,big size round flat spiral coil can be well applied to electromagnetic V-shape bending forming of small size flat sheet.
文摘The forming limit curve （FLC） can be obtained by means of curve fitting the limit strain points of different strain paths. The theory of percent regression analysis is applied to the curve fitting of forming limit experimental data.Forecast intervals of FLC percentiles can be calculated. Thus reliability and confidence level can be considered. The theoretical method to get the limits of limit strain points distributing region is presented, and the FLC position can be adjusted according to practical requirement. Method for establishing FLC with high reliability using small samples is presented at the same time. This method can make full use of the current experimental data and the previous data.Compared with the traditional method that can only use current experimental data, fewer specimens are required in the present method to obtain the same precision and the result is more accurate with the same number of specimens.
