变厚度轮辐强力旋压成形过程的分析

利用ABAQUS/Explicit模拟了变厚度轮辐双道次强力旋压过程,给出了建模和分析结果.轮辐旋压成形伴随板坯的剧烈减薄,收口区域较难成形,减薄率达50%,在计算中,轮辐有限元网格畸变严重,为此运用ALE技术改善网格质量,提高了计算精度.对模拟的旋压轮辐厚度与实验测量值进行了对比,二者吻合较好,验证了计算模型和结果的可靠性.通过ABAQUS/Standard计算了轮辐旋压成形后的回弹变形量和残余应力,分析成形后轮辐等效应变分布及回弹特征,研究发现,回弹变形量与旋压成形时壁厚变化量成正比.

Finite element simulation for the spinning process of an automobile spokes with varying thickness

The ABAQUS/Explicit was used to model the two-pass power spinning process of the automobile spoke with varying thickness,and the elastic-plastic finite element method(FEM) was carried out to simulate the forming and springback.The severe thinning of a blank was generated with the spinning proceeding,and the formability becomes low at the close up of the spun spoke due to the thickness reduction of 50%.During the simulation,because the FE meshes at the deformation area were distorted seriously,the Arbitrary Lagrange Euler(ALE) technology was used to prevent the mesh distortion and improve the calculation accuracy.The simulated thickness of the spun spoke has good agreement with the measured thickness from experiment.The springback and the residual stress in a spun spoke were calculated by ABAQUS/Standard.The distribution of equivalent plastic strain and springback characteristic are analyzed,and the springback is proportional to the thickness reduction.