韧性断裂准则在超高强钢辊弯成形工艺中的应用

对某牌号的超高强钢进行拉伸、弯曲、V型件辊弯成形试验,对比常用的6种韧性断裂准则,得出这6种韧性断裂准则均不能给出一个适用于板料各种工艺下断裂的固定临界值。根据辊弯成形工艺特点,采用Brozzo韧性断裂准则,预测相对弯曲半径R/T=2下的超高强钢辊弯成形的破裂现象。预测结果与实验结果表明,Brozzo韧性断裂准则可以应用于超高强钢辊弯成形中。     

Parameter Calibration of GTN Damage Model and Formability Analysis of 22MnB5 in Hot Forming Process

Hot forming of high strength steel at elevated temperatures is an attractive technology to achieve the lightweight of vehicle body. The mechanical behavior of boron steel 22MnB5 strongly depends on the variation of temperature which makes the process design more difficult. In this paper, the Gurson–Tvergaard–Needleman (GTN) model is used to study the formability of 22MnB5 sheet at different temperatures. Firstly, the rheological behavior of 22MnB5 is analyzed through a series of hot tensile tests at a temperature range of 600-800 °C. Then, a detailed process to calibrate the damage parameters is given based on the response surface methodology and genetic algorithm method. The GTN model together with the damage parameters calibrated is then implemented to simulate the deformation and damage evolution of 22MnB5 in the process of high-temperature Nakazima test. The capability of the GTN model as a suitable tool to evaluate the sheet formability is confirmed by comparing experimental and calculated results. Finally, as a practical application, the forming limit diagram of 22MnB5 at 700 °C is constructed using the Nakazima simulation and Marciniak–Kuczynski (M–K) model, respectively. And the simulation integrated GTN model shows a higher reliability by comparing the predicted results of these two approaches with the experimental ones.     

马氏体超高强钢钢管开裂原因分析

采用马氏体超高强钢加工的矩形钢管经酸洗除锈后发生开裂，通过实验室模拟酸洗试验、残余应力分析及氢含量测定，对钢管开裂的原因及机理进行分析。结果表明:钢管开裂是由于酸洗导致的氢致脆性开裂，钢管成型过程中产生的弯角内壁张应力、原始微裂纹以及酸洗吸氢是导致开裂的主要因素，从优化钢管成型及酸洗工艺等方面提出预防和改进措施。     

双层不锈钢管三辊斜轧数值模拟与参数优化

设计了一种核电站一回路主管道用双层不锈钢管的复合成形工艺,解决了传统锻造或铸造工艺成品长度受限的问题,同时满足了复杂工作环境对管道性能的特殊要求。采用Deform-3D有限元模拟软件对外层21-2N奥氏体耐热不锈钢与内层12Cr-12Ni马氏体耐热不锈钢的双层套管三辊斜轧成形过程进行了模拟研究与参数优化,分析了双层不锈钢管的内外层变形情况、应力应变场及温度场的分布规律,并通过设计正交试验获得了最优变形的参数组合。模拟结果表明,三辊斜轧过程中,等效应力、等效应变与温度的最大值均集中在外层管与轧辊的接触区,且外层管整体性能参数要大于内层管。通过正交设计试验的极差分析与方差分析,最终获得最优变形参数为粗轧温度1 100°C,送进角8°,轧辊转速200r/min。     

14MnMoVN低合金钢板气割坡口冷作成形的裂纹

本文介绍了14MnMoVN 钢板气割坡口冷作成形裂纹的研究结果。在气割14MnMoVN 钢板的焊接坡口时,如采用同厚度低碳钢板的气割参数,气割热影响区在冷弯时有产生裂纹的可能。金相观察表明.在气割面上有一莱氏体层存在。开裂过程的观察表明,此莱氏体层塑性很低,在弯曲时首先产生小裂纹,在一定条件下这种裂纹将要向母材扩展。从减少或去除莱氏体层这一观点出发,中提出了一些防止产生冷作成形裂纹的工艺措施.     

利用正交试验设计优化冷弯成形工艺参数

冷弯成形工艺参数的设计对冷弯成形产品质量有重要影响。本文对方矩形管冷弯成形过程中机架间距、摩擦因数和轧制速度的不同取值水平通过正交试验设计,利用Abaqus有限元软件的显式非线性动态分析对所设计试验仿真模拟,得到了每道次轧制过程中带钢边部最大纵向应变最小时各个道次3个工艺参数的最佳取值。并用优化后的参数进行仿真和验证,得到各道次带钢边部最大纵向应变比优化前要小,优化后第4~第10道次带钢纵向应变极值相对接近,产品边部拉伸小,并且边部拉伸分布比较均匀,有效改善了产品质量。     

DP980高强钢U形弯曲实验与数值模拟

为了评估DP980高强钢材料的成形与回弹特性,通过加载-卸载实验与单向拉伸-压缩循环加载实验,获得了考虑包申格效应的吉田-上森硬化模型参数,并对DP980高强钢的U形弯曲实验进行了研究。实验结果表明,DP980高强钢U形件在凹模圆角处易开裂,在成形过程中需减小压边力并增大凹模圆角。由于材料的回弹量与施加的压边力有关,可通过增大压边力来减小U形件的回弹,但压边力过大又可能导致开裂,因此,需合理选择压边力。同时,对U形件成形后的回弹进行仿真分析,仿真中分别采用等向硬化模型与吉田-上森硬化模型,通过将实验数据与模拟的回弹结果进行对比分析发现,采用吉田-上森硬化模型的仿真结果与实验结果吻合良好,证明了吉田-上森硬化模型模拟回弹的准确度较高,可以应用于回弹仿真中。     

Ductile fracture model in the shearing process of zircaloy sheet for nuclear fuel spacer grids

Features of sheared edges are predicted based on material properties of Zircaloy obtained from the tensile test and ductile fracture model such as the Gurson-Tvergaard-Needleman (GTN) and Johnson-Cook models. The sheared edges formations are numerically analyzed in each ductile model. An appropriate ductile fracture model is selected to study the relative depth of sheared edges with respect to process parameters. The tendency of failure parameters that are affected by sheared edges and fracture duration is investigated. We applied changes on parameters of failure models to show that the punch force curve and the ratio of characteristic lengths could be coincided, which led us to conclude that the GTN and Johnson-Cook models are equivalent. In the Johnson-Cook model, however, the characteristic length of the sheared edges does not change as each failure parameter reaches a critical value. Hence, the FE prediction model for forming defects is developed using the GTN failure model. Finally, the characteristic length of sheared edges have been measured using the FE prediction model for shearing process parameters such as punch velocities, clearance, and tool wear. Our results showed that the punch-die clearance is the most significant factor that affects forming defects when compared to other factors.     

电位法测试导体表面裂纹深度研究

针对导体构件表面裂纹检测问题，采用三点弯曲法模拟多种自然裂纹试样。研究了钢、铝合金中表面裂纹的电位法测量精度，得出不同材料的裂纹扩展规律。结果表明，电位法对钢合金表面裂纹的测量精度约为0．1mm，但对铝合金的测量精度较差，这是因为铝合金中的裂纹存在粘连现象，使测试结果较实际值偏小，但测量误差可控制在20％以内。     

基于厚板的三辊滚弯成形数值模拟及优化

滚弯成形由于结构简单、加工效率高而被广泛用于工业制造领域.首先,介绍了三辊滚弯技术的成形原理,借助几何模型对成形半径和上辊压下量之间的关系进行推导;然后,使用有限元分析软件ABAQUS对三辊滚弯成形的圆形截面工件进行数值模拟,从模拟结果分析了成形过程中的板材应力分布以及成形半径大小.鉴于板材加工过程中无法避免的回弹现象...     

薄壁钢管内胀推弯成形数值模拟及实验研究

针对薄壁管材弯曲成形过程中内壁起皱、外壁拉裂等成形缺陷,采用内胀推弯工艺成形规格为Φ30mm×0.3mm的1Cr18Ni9Ti薄壁管材。有限元模拟了不同内胀压力下,薄壁管成形性能和壁厚分布,并进行了实验研究。结果表明,该工艺可以很好的解决内壁起皱、外壁拉裂等成形缺陷,对生产实践具有一定的指导意义。     

Prediction of damage in small curvature bending processes of high strength steels using continuum damage mechanics model in 3D simulation

Sheet metal bending of modern lightweight materials like high-strength low-alloyed steels (HSLA) is one major challenge in metal forming, because conventional methods of predicting failure in numerical simulation, like the forming limit diagram (FLD), can generally not be applied to bending processes. Furthermore, the damage and failure behaviour of HSLA steels are changing as the fracture mechanisms are mainly depending on the microstructure, which is very fine-grained in HSLA steels composed with different alloying elements compared to established mild steels. Especially for high gradients of strain and stress over the sheet thickness, as they occur in small curvature bending processes, other damage models than the FLD have to be utilised. Within this paper a finite element (FE) 3D model of small curvature bending processes is created. The model includes continuum damage mechanics model in order to predict and study occurring failure by means of ductile coherence loss of the material and crack formation with respect to influencing process parameters. Damage parameters are determined by inverse numerical identification method. The FE-model is strain based validated considering the deformation field at the outer bending edge of the specimen by using an optical strain measurement system. The Lemaitre based damage model is calibrated against the experimental results within metallographic analysis adapting the identified damage parameters to the bending process und thus adjusting the crack occurrence in experiment and simulation. Using this model the bendability of common HSLA steel, used for structural components, is evaluated with respect to occurring damage and failure by numerical analysis.     

TC4钛合金GTN损伤模型反向标定法研究

通过拉伸试验得到TC4钛合金载荷-位移曲线,研究反向标定法确定GTN孔洞损伤模型参数。通过有限元模拟,研究GTN模型6个待定参数对模拟结果的影响。结果表明,参数f0和fN需要通过反向标定法确定,εn可由拉伸试验确定,Sn可通过计算确定,fc和fF可由模拟结果直接给出;TC4钛合金的孔洞损伤随颈缩过程的产生迅速发展,直至断裂。     

液压油箱成型机设计及工艺参数控制

针对现有围板成型方式的不足,提出一种伸缩式的支撑方式,极大地提高了工作效率。基于金属塑性成型理论,根据板料成型过程中的塑性条件和板料卸载原理,推导出塑性成型弯曲回弹规律。基于材料力学小变形叠加原理,进行折弯辊挠度推导,应用Workbench仿真设计,得到折弯辊最小挠度尺寸。通过以上计算与仿真得出的围板成型工艺参数,保证了产品质量。     

弹塑性大变形有限元分析槽钢成型过程的位移场和速度场

应用弹塑性有限元方法, 同时考虑材料和几何双重非线性, 研究槽钢辊弯成型的位移场和速度场。文中有效的处理了动态位移加载模型, 采用三维实体单元基于 Ｐｒａｎｄｔｌ Ｒｅｕｓｓ 流动规律和 Ｍｉｓｅｓ 屈服准则及 Ｕｐｄａｔｅｄ ｌａｇｒａｎｇｉａｎ 增量迭加法分析槽钢由非稳态到稳态成型过程中金属的流动规律, 然后通过有限元程序实现了计算机冷弯成型过程的真实模拟。     

应变方式对Bi-2223/Ag超导带材中微裂纹的形成及临界电流的影响

对比研究了拉伸、弯曲和压缩3种应变方式对Bi-2223/Ag高温超导带材中微裂纹的形成以及临界电流的影响。实验结果表明:带材的临界应变值在不同的应变方式作用下表现出明显的差异。同时,超导芯中裂纹的扩展途径也有所不同,弯曲时裂纹从带材上表面向内扩展,而拉伸时裂纹的产生则具有随机性。重点讨论了带材内部微裂纹的产生机理,实验发现,带材在拉伸过程中产生轧向裂纹和横向裂纹,而在压缩过程中以轧向裂纹为主,横向裂纹较少。正是这两种裂纹的交互作用导致带材临界电流的降低。     

高强钢辊弯回弹的有限元分析

随着高强钢越来越多地应用于冷弯型钢,辊弯加工中回弹也就成了辊型设计的难点之一。文章建立了U形型钢辊弯成形回弹的有限元模拟模型,并验证了该模拟建模是可靠的。同时基于该模拟建模方法,探讨了各材料参数及工艺参数对高强钢(屈服强度300MPa~600MPa)辊弯加工产生回弹的影响规律。研究表明,在材料参数中随着屈服强度和强化系数的增加,产生的回弹明显增加;而随着强化指数和厚向异性系数的增加,产生回弹变化不明显;在工艺参数中随着弯曲角增量的增加,产生的回弹减小;随着机架间距增加,产生的回弹增加。     

New incremental methods for springback compensation by stress superposition

In forming technology, the principle of stress superposition is well known for a controlled influencing of the forming zone. The aim of stress superposition is to reach an additional plastification of the material, which can be used to compensate the springback effect, e.g. of bending angles or bending radii, to extend the forming limits of the material and to reduce the forming forces. The paper deals with two new forming process variants invented by the authors, which are based on the principle of stress superposition. The first is an air bending process using an additional roll for the incremental superposition of compressive stresses along the tensile zone of a bent sheet metal. The second is the new process of incremental tube forming, which is suitable for bending tubes two- and three-dimensionally to arbitrary contours. It is based on the combination of a spinning process with the free forming of tubes.     

四辊连续滚弯侧辊位移计算与数值模拟

在四辊卷板过程中,卷制工件的曲率主要取决于侧辊的位移量。以塑性弯曲理论为基础,对四辊连续滚弯过程中板材各阶段的变形情况进行了理论分析。根据卸载定理推导出双线性硬化模型板材的回弹曲率计算公式,建立了四辊连续滚弯侧辊位移的数学模型。利用ABAQUS有限元软件对四辊连续滚弯过程进行三维动态模拟,对仿真值和理论值进行了比较,分析了不同板厚下侧辊进给量、相对弯曲半径与成形曲率半径之间的关系。结果表明:有限元仿真误差较小,可以用来指导实践;随着侧辊进给量的增加,板厚对成形曲率半径的影响逐渐减小;成形曲率半径随着相对弯曲半径的增加基本呈线性关系变化。     

基于DYNAFORM的折边机折弯回弹研究

在数控四边折边机的加工过程中,弯曲回弹的有效控制和补偿对提高加工精度有着重要的意义.首先,本文通过对镀铝锌钢板的材料性能试验,测出不同轧延方向的抗拉强度、屈服强度、泊松比、弹性模量,拟合出真实的应力应变曲线;其次,通过位移传感器测量出折边机实际折边回弹角大小;最后,通过DYNAFORM成形仿真软件建立折边机折弯成形仿真...