The Design of a Graphical User Environment for Numerical Simulation of Powder Forming Processes

As computer simulation increasingly supports engine er ing design and manufacture, the requirement for a computer software environment providing an integration platform for computational engineering software increas es. A key component of an integrated environment is the use of computational eng ineering to assist and support solutions for complex design. Computer methods fo r structural, flow and thermal analysis are well developed and have been used in design for many years. Many software packages are now available which provi de an advanced capability. However, they are not designed for modelling of powde r forming processes. This paper describes the powder compaction software (PCS_SU T), which is designed for pre- and post-processing for computational simulatio n of the process compaction of powder. In the PCS_SUT software, the adaptive analysis of transient metal powder forming process is simulated by the finite element method based on deformation theories . The error estimates and adaptive remeshing schemes are applied for updated co -ordinate analysis. A generalized Newmark scheme is used for the time domain di scretization and the final nonlinear equations are solved by a Newton-Raphson p rocedure. An incremental elasto-plastic material model is used to simulate the compaction process. To describe the constitutive model of nonlinear behaviour of powder materials, a combination of Mohr-Coulomb and elliptical yield cap model is applied. This model reflects the yielding, frictional and densification char acteristics of powder along with strain and geometrical hardening which occurs d uring the compaction process. A hardening rule is used to define the dependence of the yield surface on the degree of plastic straining. A plasticity theory for friction is employed in the treatment of the powder-tooling interface. The inv olvement of two different materials, which have contact and relative movement in relation to each other, must be considered. A special formulation for friction modelling is coupled with a material formulation. The interface behaviour betwee n the die and the powder is modelled by using an interface element mesh. In the present paper, we have demonstrated pre- and post-processor finite elem ent software, written in Visual Basic, to generate the graphical model and visua lly display the computed results. The software consist of three main part: · Pre-processor: It is used to create the model, generate an app ropriate finite element grid, apply the appropriate boundary conditions, and vie w the total model. The geometric model can be used to associate the mesh with th e physical attributes such as element properties, material properties, or loads and boundary conditions. · Analysis: It can deal with two-dimensional and axi-symmetric applications for linear and non-linear behaviour of material in static and dyna mic analyses. Both triangular and quadrilateral elements are available in the e lement library, including 3-noded, 6-noded and 7-noded (T6B1) triangles and 4 -noded, 8-noded and 9-noded quadrilaterals. The direct implicit algorithm bas ed on the generalized Newmark scheme is used for the time integration and an aut omatic time step control facility is provided. For non-linear iteration, choice s among fully or modified Newton-Raphson method and quasi-Newton method, using the initial stiffness method, Davidon inverse method or BFGS inverse method, ar e possible. · Post-processor: It provides visualization of the computed resu lts, when the finite element model and analysis have been completed. Post-proce ssing is vital to allow the appropriate interpretation of the completed results of the finite element analysis. It provides the visual means to interpret the va st amounts of computed results generated. Finally, the powder behaviour during the compaction of a multi-level component is numerically simulated by the PCS_SUT software, as shown in Fig.1. The predict ive compaction forces at different displacements are computed and compared with the available experimental

A NON－INCREMENTAL TIME－SPACE ALGORITHM FOR NUMERICAL SIMULATION OF FORMING PROCESS

A non-incremental time-space algorithm is proposed for numerical. analysis of forming process with the inclusion of geometrical, material, contact-frictional nonlinearities. Unlike the widely used Newton-Raphson counterpart, the present scheme features an iterative solution procedure on entire time and space domain. Validity and feasibility of foe present scheme are further justiced by the numerical investigation herewith presented.

Studying Formability Limits By Combining Conventional and Incremental Sheet Forming Process

In this work it is assessed the potential of combining conventional and incremental sheet forming processes in a same sheet of metal.This so-called hybrid forming approach is performed through the manufacture of a pre-forming by conventional forming,followed by incremental sheet forming.The main objective is analyzing strain evolution.The pre-forming induced in the conventional forming stage will determine the strain paths,directly influencing the strains produced by the incremental process.To conduct the study,in the conventional processes,strains were imposed in three different ways with distinct true strains.At the incremental stage,the pyramid strategy was adopted with different wall slopes.From the experiments,the true strains and the final geometries were analyzed.Numerical simulation was also employed for the sake of comparison and correlation with the measured data.It could be observed that single-stretch pre-strain was directly proportional to the maximum incremental strains achieved,whereas samples subjected to biaxial pre-strain influenced the formability according to the degree of pre-strain applied.Pre-strain driven by the prior deep-drawing operation did not result,in this particular geometry,in increased formability.

基于Simufact Forming的半空心铆钉自冲铆接参数对铆接成形的影响研究

以1.5 mm+1.5 mm A6062铝合金为研究对象,结合单一变量设计法进行参数组合,使用Simufact forming有限元软件对铆接过程进行模拟仿真,主要研究了凹模深度、凹模凸台高度、冲头速度3个工艺参数对半空心铆钉自冲铆接成形的影响,及参数对几何特征量的影响趋势,为半空心铆钉自冲铆接工艺参数进一步优化提供有益的借鉴。

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.

铸造镁合金凝固过程数值模拟研究进展

镁合金以其轻量化、高比强度和良好的阻尼性能在汽车、航空航天等领域应用广泛。数值模拟通过再现铸造成形过程中的各类宏观和微观物理过程,可以调控组织、减少缺陷、提高力学性能和优化铸造工艺参数。本文综述了铸造镁合金在枝晶和共晶凝固组织模拟,偏析、气孔和热裂等缺陷模拟,以及力学性能预测等方面的研究现状,简要介绍了近两年在铸造镁合金成形工艺模拟方面的研究进展。最后,指出了当前铸造镁合金数值模拟研究存在的问题及发展方向。

异形零件渐进成形数值模拟及参数优化

渐进成形具有工艺灵活,适应性强等优点,受到了广泛的关注。本文以一镁合金花形异形零件为例,对其渐进成形工艺进行模拟研究。首先对其成形轨迹进行设定,之后建立有限元数值模拟模型,模拟研究不同的成形工艺参数对成形质量的影响,分析其影响规律,并给出最优的成形工艺参数,对于实际生产具有一定的指导意义。

GH2132高温合金本构模型及大断面收缩率楔横轧成形研究

采用Gleeble-3800热模拟试验机对GH2132高温合金进行等温恒应变速率压缩实验,获取该合金在变形温度900~1100℃、应变速率0.01~10 s^(-1)范围内的真应力-应变曲线。对所得流动应力曲线进行摩擦与绝热修正,以消除试样热变形过程的绝热温升效应以及和砧子与试样间接触摩擦作用对实验结果的影响后,建立了考虑应变补偿的Arrhenius型本构模型。误差分析结果表明,其相对平均绝对误差不超过7%,可用于该合金高温变形行为研究。分析了具有大断面收缩率特征的GH2132合金楔横轧轧件的成形过程模拟,进一步验证了所建本构模型的准确性,为GH2132高温合金楔横轧工艺开发奠定了基础。

融合成矿过程数值模拟信息的三维成矿预测方法研究:以安徽宣城茶亭地区为例

茶亭地区位于长江中下游成矿带南陵-宣城矿集区东北部,近年来陆续发现了多个斑岩型和矽卡岩型矿床,显示深部具有很好的热液矿床成矿潜力。目前传统的矿产勘查方法对区内隐伏矿的勘查效果不佳,制约了进一步的找矿突破。三维成矿预测是近年来隐伏矿找矿的重要手段之一,但三维预测信息的缺乏在一定程度上制约了该方法的预测效果。三维成矿过程数值模拟方法能为三维成矿预测方法提供新的预测信息,但对多元数值模拟信息的联合应用以及对三维成矿预测方法的支持能力等均有待深入研究。本文以安徽宣城茶亭地区为例,在力-热-流多场耦合的条件下对热液成矿过程进行三维数值模拟;通过将体应变增量、剪切应变增量等数值模拟变量信息与其他预测信息进行融合,实现深部找矿靶区的圈定。结果显示,成矿过程数值模拟方法可为三维成矿预测提供有效的预测信息,能显著提高预测能力;圈定的找矿靶区可为进一步的深部找矿勘查提供更为有效和可靠的线索和方向。

工艺参数对聚乳酸线材熔融沉积尺寸的影响

熔融沉积(FDM)成型中线材直径的变化对打印精度有重要影响。文中利用实验和数值模拟方法研究了单根聚乳酸线材FDM过程中从喷嘴挤出到沉积固化各阶段的直径变化。根据FDM工艺特点及材料性能,量化分析了工艺参数(喷嘴温度、挤出速度、打印速度、层高)对线材喷嘴附近、挤出胀大阶段、拉伸阶段、沉积阶段直径的影响,并推导了打印过程中线材沉积固化时直径的估算公式。研究表明,提高喷嘴温度、增大挤出速度、减少层高可有效改善打印过程中线材的尺寸稳定性,提高打印件的精度。最后,利用沉积固化时的直径公式,完成了线材直径补偿“精度实验”,补偿后打印制品尺寸精度提高了74.1%。

复杂曲率铝合金薄壁构件气胀成形技术研究

为满足复杂曲率轻量化薄壁构件快速高质量成形的需求,对5754铝合金复杂构件的气胀成形性能进行了试验与仿真研究。通过单一变量法确定了型腔气压和压边力的最佳工艺参数。结合数值模拟和成形试验,分析研究了型腔气压和压边力对构件成形性能的影响规律及成形机理。结果表明,最佳的成形气压和压边力分别为1.2 MPa和4.6 MPa。当气压小于1 MPa时,最大成形深度不断增加,最大应力位于主特征中心,壁厚分布由中心向两侧递增;当气压超过1 MPa后,最大成形深度保持不变,最大应力位于型腔中心两侧,壁厚分布由中心向两侧先减后增。当压边力小于4.3 MPa时会导致构件边缘起皱;增大压边力可有效抑制起皱,但压边力超过4.9 MPa时会增加构件局部破裂的风险。因此,采用上述最佳工艺参数能够成形质量良好的复杂曲率铝合金薄壁构件。

隧道变形自动化监控数据校验与应用分析

以一新建双线盾构隧道近距离下穿既有暗挖隧道为工程依托,通过数值模拟分析既有隧道结构的变形规律,确定变形控制关键区域,布设自动化监测点。将自动化监测值与数值模拟值进行对比分析,及时对异常数据进行去噪处理,必要时调整数值计算模型,确保无人工复测数据验证时自动化监测数据的可靠性。确定监测数据可靠后,再对关键工序(如二次注浆等)既有隧道结构进行高频实时自动化监测,及时分析既有隧道变形情况,调整施工参数,从而实现对既有隧道结构变形的精准控制。

圆柱齿轮滚轧成形数值模拟与突耳控制

滚轧成形技术可有效提高金属材料利用率、改善齿轮疲劳强度。对直齿圆柱齿轮的滚轧成形技术进行研究,推导齿面方程,实现了齿面点计算,利用DEFORM软件对直齿圆柱齿轮滚轧成形过程进行了模拟仿真,分析了等效应力场、等效应变场以及滚轧力的变化情况,明晰了各个阶段最大应变发生于坯料齿形中点偏齿根处、应力最大值在模具轮和坯料的接触处这一规律;探索了滚轧中突耳缺陷的形成机制,研究了摩擦因数对突耳的作用规律,实现了面向突耳控制的摩擦因数的优选,为圆柱齿轮的滚轧成形加工提供了理论基础。

《材料成形过程数值模拟》课程的案例型教学实践与持续改进

结合工程教育专业认证的持续改进要求,针对《材料成形过程数值模拟》课程理论性强、内容范围广、实践操作要求高的特点,推行案例型教学改革,通过导入企业工程案例、学校科研项目不断优化教学内容,通过引入企业工程师参与课程评价、反馈,不断完善评价方法。同时,与企业联合推进校企协同育人,将螺钉紧固件的热镦、热处理工艺等工程实际需求融入课程建设,促使教学内容更贴近材料成形“高精尖”制造业发展前沿,提高了工科专业仿真类课程培养学生解决复杂工程问题的能力。

小弯曲半径厚壁热揻弯管成形工艺数值模拟

针对小弯曲半径的大口径厚壁弯管成形问题,基于ABAQUS有限元模拟软件,利用Dflux子程序模拟温度场进行顺序热力耦合,对外径Φ426 mm、壁厚50 mm的钢管进行弯曲半径为2.5D的热揻弯管成形工艺过程模拟,对比了不同加热位置对弯管成形质量的影响,发现加热位置与转轴在同一平面时成形质量更高。同时,在一定参数范围内,以减薄率、增厚率、椭圆度和弯曲半径为指标,通过正交试验,结合综合评分法研究了线圈宽度、加热温度和推进速度对热揻弯管成形质量的影响。结果表明,综合得分指标随温度的升高而降低,随线圈宽度增加和推进速度加快而升高,并获取了最佳工艺参数为:线圈宽度40 mm、加热温度900℃、推进速度25 mm·min^(-1)。

铝合金汽车转向节精密铸造工艺研究

目的对某铝合金汽车转向节的精密铸造工艺进行设计与优化研究,以得到合格的铝合金汽车转向节的精密铸造工艺方案。方法结合铝合金转向节铸件的结构特征、铸件材料特性和铸造经验,在转向节铸件主体部和鹅颈部各开设一个内浇口,设计了铝合金转向节初始浇注方案;通过在初始工艺方案中铸件缺陷较严重的区域设置补缩冒口、在铸件顶部增设排气道等措施给出了铝合金汽车转向节的优化浇注方案,基于ProCAST软件建立了铝合金转向节精密铸造2种浇注方案的有限元模型,对铝合金转向节精密铸造的充型过程、凝固过程及缩孔缩松特性进行了数值模拟与分析。结果铝合金转向节铸件初始浇注方案的充型过程相对稳定流畅,铸件在凝固过程中有孤立液相区的形成,完全凝固后铸件中间部位存在大面积缩松缩孔缺陷;优化浇注方案能够控制金属液的流动、充型顺序及凝固特性,铸件的整个凝固过程基本呈中间对称分布,最后凝固区域位于补缩冒口内部,最大缩孔缩松率控制在2%以下。结论优化浇注方案的设计合理且有效,能够有效地消除铝合金转向节铸件的缺陷。

2024T3铝合金蒙皮拉形数值模拟与试验验证

蒙皮是构成飞机气动外形的关键零件,通常采用拉形工艺进行生产。基于通用分析软件ABAQUS,对2024T3铝合金蒙皮拉形进行了数值模拟,研究了板料尺寸、夹钳移动距离、模具上顶高度、摩擦因数对拉形主应变、次应变和厚度的影响,并通过试验进行验证。研究结果表明,当板料尺寸增大、夹钳移动距离减小、模具上顶高度减小、摩擦因数减小时,蒙皮的主应变减小、厚度增大,成形质量较好。

超高强度钢板精准折弯成型工艺技术研究

为解决特种车辆车体制造时超高强度钢板折弯成型存在的回弹、开裂、尺寸精度差以及成型不一致等问题,通过拉伸-压缩试验、缺口拉伸断裂试验等材料性能试验获取了材料力学性能数据,标定了材料本构模型参数,构建了超高强度钢板材料参数数据库和折弯成型数值模拟仿真平台,结合有限元模拟平台实现了不同凸模压下量对超高强钢V型自由折弯成形、回弹过程以及断裂的仿真预测,通过现场实物生产对比仿真验证的模拟结果可知,数值模拟与实物的吻合度达到90%以上,验证了有限元模拟结果的有效性和准确性,为企业提高生产效率提供了依据。

精密塑性成形技术在中国的应用与进展

介绍了精密塑性成形技术在中国的发展现状。重点介绍了致力于此领域的厂家和研究单位及其所做的工作 ,以及代表精密塑性成形技术水平的典型工件。

精锻产品精度预测技术的研究现状

发展和应用精密成形技术是一个节约能源、节约材料、提高效率的有效途径。精锻技术在汽车、宇航、机械、电子等支柱产业的发展中得到了广泛的应用。本文从成形件的弹性变形、模具的弹性变形、模具的磨损以及热胀冷缩几个方面综合论述了精锻产品精度预测技术的研究现状及存在的问题,并对其未来可能的发展趋势进行了分析和探讨。