适力压边拉深模设计

提出了一种适力压边拉深模具结构 ,在拉深过程中其压边力可以随拉深起皱规律而合理变化 ,能较好地满足拉深工艺的要求。分析了该压边机构的工作原理 。

变压边力拉伸模设计

提出了一种机械式的变压边力拉伸模结构 ,其压边力由弹簧或橡胶提供。在冲压拉伸过程中压边力可以随拉伸行程合理变化 ,能较好地满足拉伸工艺的要求。

Forming defects in aluminum alloy hot stamping of side-door impact beam

The forming defects, including thinning, rupture, wrinkling and springback, usually arising in producing a side-door impact beam, were investigated by trial and numerical simulation. A temperature-related constitutive model specific to the temperature range from 350 °C to 500 °C was established and used for the numerical simulation. The trial and numerical simulation were conducted to clarify the quantitative characteristics of forming defects and to analyze the effects of process parameters on the forming defects. Results show that the rupture situation is ameliorated and the springback is eliminated in the aluminum alloy hot stamping. The wrinkling severity decreases with increasing blank holder force (BHF), but the BHF greater than 15 kN causes the rupture at the deepest drawing position of workpiece. The forming defects are avoided with lubricant in the feasible ranges of process parameters: the BHF of 3 to 5 kN and the stamping speed of 50 to 200 mm/s.

板材充液成形过程反胀效应影响因素

研究了板材充液成形过程中影响反胀效应的因素。将反胀效应划分为初始反胀(IIB)和局部反胀(LIB)。IIB的主要参数为反胀高度率(HIb/t)和反胀压力率(pIb/t),LIB受到IIB的影响并且与成形过程中液室压力直接相关。通过数值模拟得到了半球底筒形件和平底筒形件的最优反胀参数,并优化了对反胀效应有较大影响的凸模与压边圈间隙以及压边圈入口圆角等工艺参数,使反胀效应在充液成形过程中发挥了更大的作用。最后,试验验证了数值模拟结果的正确性。

基于Deform-3D的铝合金圆筒件冲锻成形压边力模拟分析

针对铝合金板材在冲锻成形过程中的压边圈的作用、压边圈与凹模间隙、最大压边力的变化因素进行研究。采用Deform-3D软件进行数值模拟,以防止铝合金圆筒件冲锻过程出现拉裂、口部高低边与凸耳等影响其质量的问题。计算得到了铝合金圆筒件在压边圈与凹模间隙不同时的压边力曲线、载荷-行程曲线、等效应变值和损伤值,对比了不同间隙时的最终成形质量。模拟表明:薄板冲锻过程应采用压边装置防止起皱;当压边圈与凹模间隙≤3. 3 mm时,板料因压边力过大被拉裂;当两者之间间隙> 3. 3 mm时,压边力最大值总体随间隙的增大而减小,最大压边力所对应的凸模压力也减小,而最终成形时所需的力增大;最终确定了两者之间的最佳间隙为3. 6 mm。

铝合金封头成形工艺分析

铝合金材料密度小,密度只是铁的1/3,塑性高。铝的延展性好,可以通过挤压、拉伸等加工工艺制成各种零部件,耐腐蚀,铝是一个负电性很强的金属,在自然条件下表面会生成保护性的氧化膜,具有比钢铁好的耐腐蚀性,还有易强化、易表面处理和回收利用率高等特点。而随着市场对车辆轻量化的要求,铝合金板材就越来越多地运用到罐式运输车辆的罐体制造中。铝合金封头作为铝合金运油车罐体的主要部件,它的制造工艺是否合理关系到整车的质量水平和生产成本,而质量和成本的高低决定了产品在市场上的竞争力。通过对封头各种成形工艺的对比,以及对铝合金封头的技术要求和成形工艺分析,结合工厂现有设备,设计出胀形+旋边两步成形的铝合金封头成形工艺,这种工艺对模具的设计和加工精度要求不高,模具简单制作周期短,用数控切割就可以满足工艺要求,不需要机加工,是目前最经济合理的加工方法。在压边模和旋边模的设计制造中,模具与封头形状要相同,尺寸要作规律性调整。胀形与旋边成形过程中,封头的长径、短径方向要始终保持一致,注意下料尺寸的搭配,提高板材利用率。

Application of new VBHF optimization strategy to improve formability of automobile panels with aluminum alloy sheet

A VBHF(Variable Blank Holder Force) optimization strategy was employed to determine the optimal time-variable and spatial-variable BHF trajectories,aiming at improving the formability of automobile panels with aluminum alloy sheet.The strategy was implemented based on adaptive simulation to calculate the critical wrinkling BHF for each segmented binder of the Numisheet' 05 deck lid in a single round of simulation.The thickness comparison of the stamped part under optimal VBHF and constant BHF shows that the variance of the four sections is decreased by 70%,44%,64% and 61%,respectively,which indicates significant improvement in thickness distribution and variation control.The investigation through strain path comparison reveals the fundamental reason of formability improvement.The study proves the applicability of the new VBHF optimization strategy to complex parts with aluminum alloy sheet.

The Numerical Simulation of Collapse Pressure and Boundary of the Cavity Cloud in Venturi

The idea that the collapse proceeds from the outer boundary of the cavity cloud towards its center for the ultrasonic cavitation proposed by Hasson and Morch in 1980s is further developed for calculating the collapse pressure and boundaries of cavity cloud at the collapse stage of bubbles for hydraulic cavitation flow in Venturi in present research. The numerical simulation is carried out based on Gilmore＇s eouations of bubble dynamics, which take account of the compressibility of fluid besides the viscosity and interfacial tension. The collapse of the cavity cloud is considered to proceed layer by layer from the outer cloud towards its inner part. The simulation results indicate that thepredicted boundaries of the cavity cloudat the collapse stage agree.well with the exPerimental ones.It is also found that the maximum collapse pressure of the cavity cloud is several times as high as the collapse pressure of outside boundary, and it is located at a point in the axis, where the cavity cloud disappears completely. This means that a cavity cloud has higher collapse pressure or strength than that of a single bubble due to the interactions of the bubbles. The effects of operation and structural parameters on the collapse pressure are also analyzed in detail.

Turbulence Model Investigations on the Boundary Layer Flow with Adverse Pressure Gradients

In this paper, a numerical study of flow in the turbulence boundary layer with adverse and pressure gradients （APGs） is conducted by using Reynolds-averaged Navier-Stokes （RANS） equations. This research chooses six typical turbulence models, which are critical to the computing precision, and to evaluating the issue of APGs. Local frictional resistance coefficient is compared between numerical and experimental results. The same comparisons of dimensionless averaged velocity profiles are also performed. It is found that results generated by Wilcox （2006） k-co are most close to the experimental data. Meanwhile, turbulent quantities such as turbulent kinetic energy and Reynolds-stress are also studied.

钛合金马鞍形薄蒙皮热压成形起皱缺陷控制

钛合金马鞍形薄蒙皮零件采用一次热压偶合成形,容易产生起皱缺陷。以某机身TC4 0.8 mm马鞍形蒙皮为研究对象,运用成形理论和力学知识,分析起皱产生的原因及规律,提出了分型面多步热压成形工艺设计和模具压边结构设计两种控制起皱的方法。研究结果表明,受冲压成形过程中金属流动不均匀与悬空区板坯平面内压应力过大的影响,马鞍形蒙皮容易发生剪应力起皱,起皱部位一般发生在马鞍侧壁区域。采用分型面多步成形可降低零件工艺难度,优化设计模具压边结构有利于控制金属的流动趋势,从而抑制悬空侧壁区材料堆积起皱。最终,通过工艺试验,试制出表面质量完好的马鞍形蒙皮零件。

Competition of the multiple Grtler modes in hypersonic boundary layer flows

Competition of multiple Gortler modes in hypersonic boundary layer flows are investigated with the local and marching methods. The wall-layer mode （mode W） and the trapped-layer mode （mode T） both occur in the compressible boundary layer where there exists a temperature adjustment layer near the upper edge. The mode T has the largest growth rate at a lower Gortler number while the mode W dominates at larger G/Srtler numbers. These two modes are both responsible for the flow transition in the hypersonic flows especially when Gortler number is in the high value range in which the crossover of these two modes takes place. Such high Gortler numbers are virtually far beyond the neutral regime. The nonparallel base flows, therefore, cease to influence the stability behavior of the Gortler modes. The effects of the Mach number on the multiple Gortler modes are studied within a chosen Mach number of 0.95, 2, 4 and 6. When the flow Mach number is sufficiently large, e.g., Ma ≥4, the growth rate crossover of the mode T and mode W occurs both in the conventional G-β map as well as on the route downstream for a fixed wavelength disturbance. Four particular regions （Region T, T-W, W-T and W） around the crossover point are highlighted with the marching analysis and the result matches that of the local analysis. The initial disturbance of a normal mode maintains the shape in its corresponding dominating region while a shape-transformation occurs outside this region.

Improvement and application of wall function boundary condition for high-speed compressible flows

In order to develop a wall function boundary condition for high-speed flows so as to reduce the grid-dependence of the simula- tion for the skin friction and heat flux, a research was performed to improve the compressible wall function boundary condition proposed by Nichols. Values of parameters in the velocity law-of-the-wall were revised according to numerical experiments and the expression of temperature law-of-the-wall was modified based on theoretical analysis and numerical simulation. Be- sides, the formula of the heat conduction term in near-wall region was derived so that the coupling between the wall function boundary condition and CFD code was realized more accurately. Whereafter, the application study of the modified wall func- tion was carried out. The numerical case of supersonic turbulent boundary layer on a flat plate illustrated that the modified wall function produces reasonable results of skin friction and heat flux, and profiles of velocity, temperature and turbulent eddy viscosity for coarse grids with the initial wall spacing of y＋〈400, and that the modifications to the original wall function can obviously improve the simulation precision. As for the application of separation flows, it was found from the numerical cases of supersonic cavity flow and hypersonic axisymmetric compression comer that the compressible velocity law-of-the-wall originally established based on the fully-developed attached turbulent boundary layer approximately holds in the near-wall re- gion inside the separation flows, which ensures that reliable skin friction and heat flux can be given by the wall function inside the separation flows, while for the region near separation and reattachment points, the wall function gives results with a rela- tively large error, because the velocity law-of-the-wall used in the wall function takes on obvious deviation from the real ve- locity profiles near the separation and reattachment points.

A Study on the Transport Process in Gas Diffusion Layer of Proton Exchange Membrane Fuel Cells

Gas diffusion layer(GDL) plays a great important role in proton exchange membrane fuel cell(PEMFC).Water transport mechanism in GDL is still not clear.In the present study,an ex-situ transparent setup is built to visualize the transport phenomena and to measure the threshold pressure of water in GDL at different temperatures.It is found that the relationship between the breakthrough pressure and the temperature is nearly linear(i.e.the pressure decreases linearly with the increase of temperature).To avoid the problems faced by the continuum models,the pore network model is developed to simulate the liquid water transport through the carbon paper.A uniform pressure boundary condition is used in simulation and the results are similar to the ones obtained in the experiment.The reason is that the contact angle and surface tension coefficient of water in GDLs change accordingly with the change of temperature.

Characteristics of nonlinear evolution of wavepackets in boundary layers

The nonlinear evolution of a finite-amplitude disturbance in a 3-D supersonic boundary layer over a cone was investigated recently by Liu et al. using direct numerical simulation （DNS）. It was found that certain small-scale 3-D disturbances amplified rapidly. These disturbances exhibit the characteristics of second modes, and the most amplified components have a well- defined spanwise wavelength, indicating a clear selectivity of the amplification. In the case of a cone, the three-dimensionality of the base flow and the disturbances themselves may be responsible for the rapid amplification. In order to ascertain which of these two effects are essential, in this study we carried out DNS of the nonlinear evolution of a spanwise localized disturbance （wavepacket） in a flat-plate boundary layer. A similar amplification of small-scale disturbances was observed, suggesting that the direct reason for the rapid amplification is the three-dimensionality of the disturbances rather than the three-dimensional nature of the base flow, even though the latter does alter the spanwise distribution of the disturbance. The rapid growth of 3-D waves may be attributed to the secondary instability mechanism. Further simulations were performed for a wavepacket of first modes in a supersonic boundary layer and of Tollmien-Schlichting （T-S） waves in an incompressible boundary layer. The re- suits show that the amplifying components are in the band centered at zero spanwise wavenumber rather than at a finite spanwise wavenumber. It is therefore concluded that the rapid growth of 3-D disturbances in a band centered at a preferred large spanwise wavenumber is the main characteristic of nonlinear evolution of second mode disturbances in supersonic boundary layers.

MHD EYRING-PRANDTL FLUID FLOW WITH CONVECTIVE BOUNDARY CONDITIONS IN SMALL INTESTINES

In this paper, we have discussed the food movement in stomach with thermal bound- ary conditions. Eyring-Prandtl fluid model is considered. Formulation of the considered phenomena have been developed for both fixed and moving frame of references. Regular perturbation is used to find the solution of stream function, temperature profile and pressure gradient. Analysis has been carried out for velocity, ＂stream function, temper- ature, pressure gradient and heat transfer＂. Appearance of pressure gradient is quite complicated so to get the expression for pressure rise we have used numerical integra- tion. It is perceived that the velocity close to the channel walls is not same in outlook of the Eyrin^Prandtl fluid parameter taken as fl and Hartman number M. The velocity decreases by increasing β and M.

Mathematical Modelling and Experimental Investigation of Gas Flow in Minichannels and Microchannels

The first part of this study is focused on the numerical modelling and experimental investigation of transonic flow through a 2D model of the male rotor-housing gap in a dry screw compressor.Numerical simulations of the clearance flow are performed with the help of the in-house compressible Navier-Stokes solver.Experimental measurements based on the Schlieren method in Toepler configuration are carried out.The objective of the second part of the study is to derive the analytical solution of gas microflow development in a gap between two parallel plates.The microflow is assumed to be laminar,incompressible and the velocity slip boundary conditions are considered at the walls.The constant velocity profile is prescribed at the inlet.For the mathematical description of the problem,the Oseen equation is used.The analytical results are compared with the numerical ones obtained using the developed incompressible Navier-Stokes solver including the slip flow boundary conditions.

Effects of Reynolds number on the performance of a high pressure-ratio turbocharger compressor

The effects of Reynolds number on the performance of a high pressure-ratio turbocharger compressor were investigated by both experiments and numerical simulation. The experimental results show that the pressure ratio and the efficiency of the compressor respectively decrease by 7.9% and 6.9% when Reynolds number drops from 9.86×10 5 to 2.96×10 5 . The numerical simulation predicts a similar trend as the experimental results although it underestimates the deterioration of the performance under low Reynolds number conditions. According to simulation results, the boundary layer thickness increases at the inducer, which decreases the throat area and leads to smaller choke mass flow rate. The increments of the boundary thickness are relatively small at the rear part of the impeller. The boundary layer separation flow is severe. The interaction between boundary layer separation flows and leakage flows causes the high loss region at the rear part of the impeller passage under low Reynolds number condition.