考虑初始残余应力的板料弯曲回弹理论分析

在实际弯曲加工过程中,板料内部如果带有初始残余应力,将与弯曲应力发生叠加,对板料的回弹产生一定的影响。由于传统的回弹理论都没有考虑初始残余应力的影响,该文基于平面应变假设,采用服从Mises屈服准则和线性强化材料模型,推导了考虑初始残余应力的板料弯曲回弹角近似公式并基于有限元软件ABAQUS进行了残余应力板料弯曲回弹仿真对比分析。理论计算与仿真结果具有较好的一致性,验证了理论模型的正确性。研究结果表明,残余应力和厚度对板料回弹均有较大影响:沿宽度方向,不同初始残余应力处的板料回弹并不均匀;增大初始残余应力峰值和减小板料厚度均使不同初始残余应力处板料的回弹差值增大。     

钣金V形折弯成形的回弹控制研究

为了实现对钣金V形折弯回弹的有效控制,在折弯加工过程中逐渐修正材料的性能参数,从而准确计算最终的折弯深度参数.本文对板料进行几次增量式的折弯加工,获取相应的成形及回弹角度参数,并通过理论模型修正材料的性能参数值,进而利用修正后的材料参数计算折弯深度参数.实验结果表明:修正后的材料性能参数接近拉伸实验的结果,折弯成形角度的偏差小于1°.增量式折弯方法避免了由材料参数误差引起的回弹控制误差,有效提高了V形折弯回弹的控制精度."     

先进高强度双相钢弯扭复合回弹评价与试验研究

目的 针对先进高强度双相钢冲压成形后回弹量大且多种回弹形式相互作用的问题,提出弯曲–扭曲复合回弹试验评价指标与测试方法,研究双相钢强度级别和试验条件对弯扭回弹的影响规律。方法 建立板料回弹前后的几何关系,提出弯扭复合回弹评价指标,通过改变三点弯曲试验上压杆的偏转角度,开展弯扭复合回弹试验。结果 基于合理的几何关系假设提出的评价指标适用于弯扭复合回弹试验结果分析。当上压杆偏转角度为0°时,强度越高,板料弯曲回弹越明显,回弹后横截面顶点距离和2条对角线长度变化越小;随着上压杆偏转角度的增加,当上压杆偏转0°～15°时,不同强度的3种试件（DP600、DP780、DP980）的横截面顶点距离和2条对角线长度增大,其中DP600试件的横截面顶点距离变化最小;当上压杆偏转15°～45°时,3种试件共同表现出横截面顶点距离减小、一条对角线长度减小、另一条对角线长度增加,其中DP980试件的对角线长度之差最小。结论 试验数据与分析结果表明,调整三点弯曲试验中上压杆的偏转角度可以诱发不同的扭曲回弹量,进而有效控制弯曲回弹与扭曲回弹的复合程度。分别利用板料横截面顶点距离变化及2条对角线长度变化评价弯曲回...     

铝合金-聚合物复合层板弯曲回弹理论分析

针对铝合金-聚合物复合层板弯曲回弹问题,分析了复合层板弯曲过程表面层铝板及中心层聚合物的变形特征,建立了复合层板平面应变纯弯曲回弹理论分析模型.采用建立的模型预测了复合层板纯弯曲过程回弹角变化,并与实验结果进行了对比,分析了聚合物层厚度及铝合金板材力学性能对回弹的影响规律.结果表明:随着中心聚合物层厚度的增加,复合层板回弹角降低;随着表面层铝板强度的降低,复合层板回弹角减小.理论预测结果与实验结果一致,说明了本文推导的理论模型的可靠性.     

平面应变板料拉弯成形回弹理论分析

基于平面应变假设,采用服从Hill平方屈服准则和指数强化材料模型,建立了板料拉弯成形回弹量预测的理论模型。应用该模型计算了一个拉弯成形回弹实例,分析了单位宽度切向拉力、凸模圆角半径、摩擦因数及各向异性参数对板料回弹量的影响。分析结果表明,只有当中性层偏移距离超过板厚的四分之一时,增大切向拉力才能有效地控制板料回弹量,而且弯曲半径越大,增大切向拉力控制板料的回弹量越为有效,然而拉力不能无限制的增大,它的计算准则为板料最外层的等效应变应不大于极限应变。同时还表明,摩擦因数对板料回弹量的影响随切向拉力的增大变得更为显著,而各向异性参数对板料拉弯成形回弹量的影响也较为明显。与有限元数值模拟预测结果的对比表明,理论模型预测板料拉弯成形回弹量与有限元数值模拟结果很接近。     

铝合金板材磁脉冲辅助U形弯曲过程回弹数值模拟分析

目的揭示铝合金板材磁脉冲辅助弯曲成形对回弹的影响机理。方法基于两种磁脉冲辅助成形方案,采用数值模拟软件LS-DYNA,建立磁脉冲辅助U形弯曲的有限元模型。结果与准静态成形相比,磁脉冲辅助U形弯曲成形能减小板料圆角区的残余应力,方案Ⅰ板料圆角区等效塑性应变大于方案Ⅱ板料圆角区的等效塑性应变;电磁体积力能有效减小回弹,且放电能量越大,回弹角越小;磁脉冲辅助U形弯曲成形能减小板料的弹性应变能。结论相同放电电压下,方案Ⅰ的回弹控制效果好于方案Ⅱ的回弹控制效果。磁脉冲辅助U形弯曲减小回弹的主要原因是板料圆角区残余应力的减小和弹性应变能的降低。     

Influence of size effect on the springback of sheet metal foils in micro-bending

To analyze the unloading springback of sheet metal foils after micro-bending process, a constitutive model is proposed based on the surface layer model by which the sheet foil is divided into surface layer and inner portions. For the inner portion, each grain is envisaged as a composite, comprised of grain interior and grain boundary work-hardened layer. The classical composite model is then used to calculate its flow stress. For the surface layer portion, a model without grain boundary strengthening is constructed to represent the flow stress in this zone. The developed method is verified through the comparison of the calculated strain–stress curves with the tensile test results of four kinds of pure copper sheet foils with different thicknesses ranging from 0.1 mm to 0.6 mm. To investigate the effect of thickness and grain size on the springback of pure copper sheet foils, three-point bending tests are carried out. A finite element (FE) model for predicting the springback in micro-bending process is further developed, which takes into account the deformation behavior and orientation of each grain. The influences of grain size and thickness on the springback of sheet foils are investigated. The research results show that the decrease of sheet foil thickness or the increase of grain size results in a big springback. The scatter of springback angle is mainly attributed to the elastic anisotropy of surface grains and increases with the reduction of grains along the thickness direction. A good agreement between the experimental results and the analytical calculations shows that the developed FE model can predict the springback of sheet metal foils well in micro-bending process.     

An analytical model for predicting springback and side wall curl of sheet after U-bending

An analytical model for predicting sheet springback after U-bending is proposed in this paper based on Hill48 yielding criterion and plane strain condition. The model takes into account of the effects of deformation history, thickness thinning and neutral surface shift on the sheet springback of U-bending. Three rules for material hardening – kinematic, isotropic and combined hardening – have been used to consider the effect of complex deformation history that has undergone stretching, bending, and unbending deformations on the sheet springback. The model is applied to the benchmark of NUMISHEET’93 2-D draw bending problem. It indicates that the springback is overestimated when isotropic hardening is applied, while is underestimated when kinematic hardening is applied. For reverse loading problem, the combined hardening is a good approach to the practical material. In addition to that, the effects of blank holding force, friction coefficient between sheet and tools, sheet thickness and anisotropy have been investigated. When the shifting distance of neutral surface exceeds one-fourth of sheet thickness, the springback can be reduced effectively by increasing the blank holding force and friction between sheet and die. And the springback increases with anisotropy and friction between sheet and punch, and decreases with the sheet thickness.     

基于正交试验的S形板料折弯工艺研究

针对典型的S形板料折弯工艺进行了分析.应用DYNAFORM有限元模拟软件,分析了S形板料折弯后的内外层等效应力、等效应变分布及回弹前后的应力应变变化,对其折弯过程中的回弹机理进行了 研究.通过正交试验的直观及方差分析确定了影响板料回弹若干关键因素的主次顺序,节省了现场试验的成本,对S形折弯件的精密化生产有一定的指导意...     

考虑材料参数变化的高强钛管数控弯曲回弹行为研究

目的研究钛管数控弯曲回弹角、回弹半径的变化规律,揭示回弹角和回弹半径变化特征的形成机制。方法基于有限元软件平台,建立考虑收缩应变比-弹性模量变化的Ti-3Al-2.5V钛管数控弯曲成形及回弹全过程的有限元模型。结果回弹角随弯曲角和相对弯曲半径的增加而增加;回弹半径在弯曲角小于30°时,随弯曲角的增加而先变化很小,后显著增加;弯曲角大于30°时,回弹半径随弯曲角的增加而逐渐减小。回弹半径随相对弯曲半径的增加而增加。弯曲角越大,应力分布区域越大,回弹变形越大;相对弯曲半径越大,弯管中处于弹性变形的区域占总变形区域的比例较大,回弹变形越大。结论考虑两参数变化时对回弹角和回弹半径的变化趋势无显著影响,但获得的回弹角和回弹半径均大于忽略两参数变化时的值;考虑收缩应变比-弹性模量变化时,弯曲变形区沿外脊线的拉应力大于忽略两参数变化时的拉应力,卸载回弹时,管材发生大的弹性恢复,表现为回弹角和回弹半径的增加。     

型材拉弯的力学与回弹分析

回弹是弯曲成形中普遍存在的现象,是由卸载过程中内力重新分布引起的,回弹的存在直接影响弯曲件的成形精度.本文针对转台拉弯成形过程,对等边型材等曲率拉弯进行了应力-应变分析,并按照卸载预拉力与不卸载预拉力两种情况对工件回弹进行了研究与探讨,得到两组半径回弹率理论曲线.通过与试验结果对比,不卸载拉力计算的结果与试验值比较吻合.     

双向梯形夹芯板柱面弯曲成形回弹分析

整体弯曲成形是制造曲面夹芯板高效且经济的方法,其成形特点与回弹预测是重点研究方向。采用结合有限元的半解析法对双向梯形夹芯的力学参数进行推导,获得夹芯等效弹性常数,分析上、下面板不等厚夹芯板柱面弯曲成形时面板与夹芯的变形特点及应力中性层的变化,在此基础上建立夹芯板平面应变弯曲回弹理论计算模型,预测夹芯板弯曲成形的应力分布与回弹,并与数值模拟及多点弯曲成形实验结果进行对比。结果表明:夹芯板回弹量与中厚板十分接近,回弹量较小,易于控制成形精度;理论预测的横截面切向应力与回弹都偏大,其中上面板应力相对误差在2.9%以内,下面板应力相对误差在6.5%以内,下面板纵向中心截面线误差在1.0mm范围内,各项误差均在很小范围内,验证了本工作回弹计算模型的准确性。     

Adaptive through‐thickness integration for accurate springback prediction

Accurate numerical prediction of springback in sheet metal forming is essential for the automotive industry. Numerous factors influence the accuracy of prediction of this complex phenomenon by using the finite element method. One of them is the numerical integration through the thickness of shell elements. It is known that the traditional numerical schemes are very inefficient in elastic–plastic analysis and even for simple problems they require up to 50 integration points for an accurate springback prediction. An adaptive through‐thickness integration strategy can be a good alternative. The main characteristic feature of the strategy is that it defines abscissas and weights depending on the integrand's properties and, thus, can adapt itself to improve the accuracy of integration. A concept of an adaptive through‐thickness integration strategy for shell elements is presented in this paper. Its potential is demonstrated using two examples. Calculations of a simple test—bending a beam under tension—show that for a similar set of material and process parameters the adaptive rule with seven integration points performs significantly better than the traditional trapezoidal rule with 50 points. Simulations of an unconstrained cylindrical bending problem demonstrate that the adaptive through‐thickness integration strategy for shell elements can guarantee an accurate springback prediction at minimal costs. Copyright © 2007 John Wiley & Sons, Ltd.     

Investigation of Springback of Metallic Sheets at Small Strains

Abstract:  The bending process of an aluminium alloy and a high‐strength steel is analysed using the cylindrical bending test of 1 (Proceedings of the 5th International conference and workshop on numerical simulation of 3D sheet forming processes, 2002 , Jeju Island, South Korea). Despite its simplicity, it is now well known that this test is difficult to reproduce numerically. Indeed, it involves small plastic strains but large springback and exhibits complex contact boundary conditions providing severe benchmark characteristics. In order to obtain reliable results to be used for the validation of finite element models or simulations, particular attention has been paid to the fine measurement of several experimental parameters using a high‐resolution video camera. Several geometrical and contact parameters, as well as the springback angle, are determined. The springback results are compared with analytical results obtained using a classical bending model. It is shown that the agreement is good if the work‐hardening is identified within a small strain range, corresponding to the one covered during the test, as it mainly involves small deformations, pure bending and a weak anticlastic effect. Moreover, the decrease in the apparent modulus as a function of plastic strain leads to a more accurate measurement of the variation in the springback angle.     

Coupling effects of material properties and the bending angle on the springback angle of a titanium alloy tube during numerically controlled bending

The significant springback after the numerically controlled (NC) bending of a titanium alloy tube has an important influence on the precision of the shape and size of the bent tube. This springback depends on the material properties of the tube, the bending angle, and especially their coupling effects. The influence of some material properties and the bending angle on the springback angle in the NC bending of a TA18 tube were investigated using a three-dimensional (3D) elastic–plastic finite element model. Using multivariate and stepwise analyses, the coupling effects of the bending angle and the material properties on the springback angle during NC bending were revealed. It was observed that Young’s modulus, yield stress, the strain hardening coefficient and exponent, and the thickness anisotropy exponent, as well as interactions of these parameters with the bending angle, have a significant influence on the springback angle. The bending angle, yield stress, and hardening coefficient have positive effects on the springback angle, and Young’s modulus, the hardening exponent, and the thickness anisotropy exponent have negative effects. The influence of the material properties of the titanium alloy increases with the bending angle. Young’s modulus and the strain hardening coefficient and exponent have the greatest influence on the springback angle. The results will be very useful in predicting, compensating for and controlling the springback of titanium alloy tubes during NC bending.     

宽板大曲率半径纯弯曲回弹量理论分析

针对各向异性板料的大曲率弯曲回弹问题,建立了服从Hill屈服准则和指数强化模型的平面应变纯弯曲的回弹理论模型。应用该模型计算了Numisheet’2002无约束柱面弯曲回弹的考题,与实验结果和其它理论模型计算值的对比表明,模型的回弹结果与实验值很接近,其精度优于其它算法。同时还表明,屈服准则的选取对预测板料回弹量有着较大影响,而强化模型的影响则不是很显著。     

板料弯曲回弹影响因素的有限元模拟研究

通过静态力学、动态力学实验方法,研究了热致性液晶聚合物(LCP)的种类对环氧树脂共混物在不同温度下的拉伸强度和应力-应变曲线的影响,通过TEM观察了共混物的相形态结构.结果表明,反应型液晶聚合物(LCPU)比其它种类的液晶聚合物对环氧树脂的改性效果更好;在不同温度下,其拉伸强度和应力～应变行为均比其它材料优越;固化物的动态力学结果表明:反应型的液晶聚合物键入了固化网络,出现新的松弛,TEM结果表明,反应型的液晶聚合物在基体材料中形成大小在nm数量级的液晶聚集微区,没有反应基团的液晶聚合物PHBHT在10%的加入量下,与环氧的共混物结构也有液晶聚集微区产生,但是聚集区大小在微米量级.     

板料成形过程回弹的三维检测与评价方法研究

针对板料成形回弹数值难以精确测量、实际误差无法全面估计等问题,采用近景摄影测量系统和面扫描系统相结合的测量方法对板料的成形过程回弹进行了研究,提出了一种精确获得板料成形空间回弹量的新方法,研究了该方法的原理、程序和步骤.结合本方法定义了板料回弹评价的新指标S,该指标用空间回弹值和x、y、z三个方向回弹值组成的向量来表示,以某型号冰箱门外壳为实例进行了成形回弹量的检测和评价.结果表明:对于冰箱门外壳大表面,三维空间回弹数值的影响主要来自z方向,x方向回弹数值为0,y方向影响较小,三维空间回弹数值大小和方向与z方向回弹值的大小和方向保持完全一致.     

Twist springback characteristics of dual-phase steel sheet after non-axisymmetric deep drawing

This paper aims to investigate the twist springback characteristics of advanced high strength steel sheet subjected to deep drawing. A C-rail benchmark, which leads to a particularly pronounced twist springback characteristics, was developed. For an accurate numerical modeling of the process, a non-quadratic anisotropic yield criterion integrated with combined isotropic and kinematic hardening model was used to describe the strain-stress behavior including anisotropy and Bauschinger effects. The corresponding mechanical experiments, namely uniaxial tension and forward-reverse simple shear tests were performed to determine the material parameters. The digital image correlation technique was applied for component tests as well as the deformation and stress-strain analysis. The experimental validation of the elastic-plastic finite element model was assessed by comparing maximum in-plane strain, thickness reduction distribution and twist springback of the drawn rail. To explore the source of twist springback, the deformation associated with in-plane stress and bending moment was analyzed. The results indicate that the bending moment before springback caused by non-symmetric stress states play an important role in twist springback and control. Certain regions of the die radius were varied in a numerical analysis to control the bending moment for the minimization of twist springback as well as the preliminary results of the relationship between the ratio of variable die radius and twist springback.     

镁合金板材等通道弯曲变形模拟与实验

目的通过设计一种等通道弯曲变形工艺,实现镁合金板材沿厚度方向较均匀的剪切应变。方法利用ABAQUS数值模拟并结合应变非均匀性评估方法,系统研究不同厚度镁合金板材在相同变形参数下剪切应变分布特征,比较实验结果说明模型准确性。结果等通道弯曲变形可以在不同厚度板材中实现较为均匀的剪切应变,且随着板材厚度的增加而提高。关于成形力的模拟和实验结果吻合良好,表明数值模拟方法能够较好实现ECAB变形过程的预测。结论由于该工艺能够引入均匀剪切应变,有望在镁合金板材组织和织构优化方面取得研究与应用价值。