不同初始结构环壳液压成形理论分析与数值模拟

针对用环壳液压胀形工艺制作弯头过程中存在的失稳起皱问题,从理论上分析了环壳的初始形状对其成形的影响,并用动态有限元分析软件DYNAFORM对其成形进行了数值模拟,模拟结果与实验结果基本一致,同时对起皱原因进行了分析,研究结果表明,通过选择合适的胀前壳体结构,可以有效地改善胀形过程中壳体存在的失稳起皱问题。     

环壳初始结构对其液压胀形过程的影响

本文针对用环壳液压胀形工艺制作弯头过程中存在的失稳起皱问题,从理论和实验上分析了环壳的初始形状对其成形的影响。研究结果表明,通过选择合适的胀前壳体结构,可以有效地改善胀形过程中壳体存在的失稳起皱问题。     

双母线椭球壳液压胀形过程应力与变形分析

通过设计双母线椭球壳作为胀形前预制壳,解决了初始轴长比大于2的椭球壳在胀形过程赤道带起皱的问题。为分析双母线椭球壳胀形过程的应力与变形特点,进行初始轴长比为1.5和1.7的双母线椭球壳液压胀形试验研究和数值模拟。通过数值模拟,揭示双母线椭球壳无模胀形避免起皱的机理。在变形过程中,赤道带板料一致承受双向拉应力作用;赤道带焊缝处在变形初始阶段存在纬向压应力,产生的原因是焊缝处多面壳体二面角展开过程存在弯曲效应,在焊缝外表面带来附加压应力,该压应力不足以引起失稳起皱;随压力升高,壳体各处均受双向拉应力作用。通过试验研究,绘制典型点的应力轨迹图,揭示双母线椭球壳胀形过程中塑性变形发展及壁厚变化规律。极带最先发生塑性变形,随着压力的升高,塑性逐渐向赤道线方向发展,赤道线最后发生塑性变形;壳体侧瓣中心线比焊缝线更容易发生塑性变形。极带的变形量大于赤道带,所以壁厚的最大减薄位于极点,最大减薄率分别为10.4%和16.3%。最终获得合乎设计要求的椭球壳。     

薄壁深抛物线形零件固体颗粒介质成形工艺

薄壁抛物线形壳体成形过程为拉深和胀形两种变形模式的复合,极易发生起皱和破裂。固体颗粒介质成形是采用固体颗粒代替刚性凸模或凹模(或弹性体、液体)对板料进行成形的工艺。板材在颗粒介质内压的作用下成形,可以有效防止抛物线形件拉深成形过程中侧壁的起皱;由于颗粒内压是非均匀分布的,故可以有效控制抛物线形件成形过程中的破裂,提高板材的成形极限。根据固体颗粒介质成形工艺的特点,提出了两次成形薄壁深壳体零件的工艺,建立了数值分析模型,通过数值模拟和试验对该成形过程和工艺参数进行了分析。结果表明,采用固体颗粒介质成形工艺过程简单、成形工件壁厚分布均匀、表面质量好、回弹小。     

用中心管限位的椭球壳无模液压成形试验研究

理论与实践均证明,长短轴比大于2的椭球壳体在自由胀形时会在赤道附近起皱,其原因是由于存在纬向压应力。首次提出采用带中心管约束法整体无模胀形技术,对长短轴比为2的椭球壳体进行液压胀形试验研究,得到了椭球壳体胀形时应变分布及尺寸变化规律。试验结果表明：在中心管约束下的椭球壳体胀形可以较好地控制椭球轴长比。椭球状壳体在胀形过程中经历焊缝起皱凸起,后又在更高内压的作用下逐渐消皱的过程。塑性变形首先发生在赤道焊缝处,随后球瓣靠近南北极的部位也发生塑性变形,并由赤道和极板向温带区域扩展。用此方法所获得的壳体可以直接用于椭球形水塔。     

双层金属保温容器同步液胀成形过程的数值模拟

为了实现足球、排球形双层金属保温容器的同步液胀成形，本文采用大型商用有限元软件Dynaform对其成形的过程进行了数值模拟，并就加载压力和加载时间对保温容器外壳胀形量的影响进行了分析。结果表明，保温容器外壳的最大主应变及最大壁厚减薄率主要分布在焊缝附近，花纹纹线附近的厚度不均现象比其它部位更明显；随着加载压力和加载时间的增加，保温容器外壳的胀形量增大，贴模性更好，花纹纹理更加清晰。     

无缝管与有缝管液压成形性比较

通过对无缝管和有缝管在不同内压下自然液压胀形过程的有限元数值模拟,分析比较了管材胀形后的轮廓形状分布、壁厚分布和最大成形高度,探讨了焊缝材料性能对上述三个成形参数的影响,结果表明:无缝管胀形后轮廓形状对称,而有缝管胀形后轮廓形状不对称,并且这种不对称性随着内压增大而加剧;无缝管胀形后壁厚沿环向分布均匀,而有缝管胀形后,距焊缝对称中心0~15°之间的壁厚沿环向分布不均匀,距焊缝对称中心15°~180°之间的壁厚基本上呈均匀分布,且壁厚值和同种材料的无缝管在相同条件下胀形的壁厚值接近;焊缝材料强度比基体材料强度高,则极限成形高度大。     

液压胀形汽车桥壳的数值模拟及其试验研究

用有限元方法对液压胀形的汽车桥壳进行了数值模拟,得出轴向压缩量与液体胀形压力间的合理加载路径.通过试验和模拟对比分析了第一次胀形时液体压力相对管坯轴向压缩量恒定不变、液体压力按轴向压缩量线性变化、极限失稳及胀裂的情况,揭示出起皱的主要原因是液体压力过低,起皱后不利于后续胀形,而胀裂的主要原因是液体压力过高;第二次胀形时试件退火是最终成形成功的重要影响因素.模拟结果与相同条件下的试验结果对比,最大误差5 9%.     

不锈钢焊管焊缝n值对管材胀形性能的影响

通过对不锈钢焊管焊缝和母材的对比试验及有限元模拟,揭示了两者出现差异时,管液压胀形时破裂发生的位置：当焊缝的材料硬化指数n值低于母材时,胀形时破裂将从焊缝中心线处发生;当焊缝的n值高于母材时,胀形时破裂将从焊缝的边缘发生.以此提供了有效评价不锈钢焊管在胀形中成形性能的判断依据.     

矩形金属波纹管机械胀形工艺仿真分析

针对矩形金属波纹管不易成形的问题,采用数值模拟的方法,研究了不同成形工艺下波纹管的变形特点.建立了纯机械胀形、外加固定模具机械胀形、内加固定模具机械胀形三种矩形金属波纹管成形工艺有限元模型,对比了不同工艺下波纹管的应力应变、壁厚、轮廓等变形特征,分析了成形过程中的变形机理.研究发现,采用纯机械胀形工艺的波纹管波纹形状呈...     

Postbuckling of shear deformable FGM cylindrical shells surrounded by an elastic medium

This paper presents a study on the postbuckling response of a shear deformable functionally graded cylindrical shell of finite length embedded in a large outer elastic medium and subjected to axial compressive loads in thermal environments. The surrounding elastic medium is modeled as a tensionless Pasternak foundation that reacts in compression only. The postbuckling analysis is based on a higher order shear deformation shell theory with von Kármán-Donnell-type of kinematic nonlinearity. The thermal effects due to heat conduction are also included and the material properties of functionally graded materials (FGMs) are assumed to be temperature-dependent. The nonlinear prebuckling deformations and the initial geometric imperfections of the shell are both taken into account. A singular perturbation technique is employed to determine the postbuckling response of the shells and an iterative scheme is developed to obtain numerical results without using any assumption on the shape of the contact region between the shell and the elastic medium. Numerical solutions are presented in tabular and graphical forms to study the postbuckling behavior of FGM shells surrounded by an elastic medium of tensionless Pasternak foundation, from which the postbuckling results for FGM shells with conventional elastic foundations are also obtained for comparison purposes. The results reveal that the unilateral constraint has a significant effect on the postbuckling responses of shells subjected to axial compression in thermal environments when the foundation stiffness is sufficiently large.     

KM6载人宇宙飞船试验舱有限元分析

KM6载人宇宙飞船整体试验舱是由四个椭球壳、两个带筋圆柱壳、一个锥壳和三组大型法兰组成的复杂大型真空容器,它分为主舱和辅舱。这里采用有限元法对辅舱进行了强度、刚度和屈曲分析,并提出了改进方法,为设计人员直接采用,该试验已通过压力试验,实验证明了给出的结果的正确性。     

汽车外形的多细节层次描述

针对复杂的汽车外形，提出一种图形图像混合描述新方法。该方法用深度图像描述汽车复杂外形，根据其窗洞形状，建立简单的初始网格。在此基础上，通过适合于窗洞描述的网格自动细化算法得到其精细网格，并通过深度图像采样和坐标变换，建立起汽车外形的多细节层次描述。与现有采用纯图形技术实现的方法相比，该方法算法简单，自动化程度高，造型形态规整对称，适合于网络传输和协同交互设计。     

Multidisciplinary optimization of a stiffened shell by genetic algorithm

Vibration analysis of simply supported rotating cross-ply laminated stiffened cylindrical shell is performed using an energy approach which includes variational and averaging method. The stiffeners include rings and stringers. The equations are obtained by Rayleigh-Ritz method and Sander’s relations. To validate the present method, the results are compared to the results available in other literatures. A good adoption is observed in different type of results including isotropic shells, rotating laminated shells, stiffened isotropic shells and stiffened laminated shells. Then, the optimization of parameters due to shell and stiffeners is conducted by genetic algorithm (GA) method under weight and frequency constraints. Stiffener shape, material properties and dimensions are also optimized.     

Elastoplastic dynamic instability of long circular cylindrical shells under pure bending

This paper presents a numerical study which is concerned with the prediction of the response and instabilities in long circular cylindrical shells under dynamic pure bending. Of particular interest is the response of such shells, bent into the plastic range of the material, and the various instability characteristics of the shells under dynamic bending (sudden step load). It was found that the major deformation characteristic of the shells is essentially similar to that observed in the static bending when the applied moment is much smaller than the critical dynamic moment. However, when the applied moment is close to the critical dynamic moment, the ovalization of the shell cross-section was found to be localized over a length of several shell diameters in the central region, even though the response of the shell curvature was shown to be still stable in this case. When the applied moment reaches the critical dynamic moment, the response of the shell curvature was shown significantly increasing with time and the shell buckled catastrophically. For thicker shells, it was found that the development of localized ovalization of the shell cross-section is the major factor that causes shell dynamic instability. For thinner shells, however, besides the localized ovalization, the bifurcation induced by short wavelength ripples on the compressed side of the shell was also observed in the initial buckling patterns. After the bifurcation, the initial buckling pattern was replaced by the final postbuckling mode characterized by a localized sharp cupping in the centre of the shell.     

Modal analysis of conical shell filled with fluid

As a basic study on the fluid-structure interaction of the shell structure, a theoretical formulation has been suggested on the free vibration of a thin-walled conical frustum shell filled with an ideal fluid, where the shell is assumed to be fixed at both ends. The motion of fluid coupled with the shell is determined by means of the velocity potential flow theory. In order to calculate the normalized natural frequencies that represent the fluid effect on a fluid-coupled system, finite element analyses for a fluid-filled conical frustum shell are carried out. Also, the effect of apex angle on the frequencies is investigated.     

A viscous shell formulation for the analysis of thin sheet metal forming

A finite element method to analyse large plastic deformations of thin sheets of metal is presented. The formulation is based on an extension of the general viscoplastic flow theory for continuum problems to deal with thin shells. Axisymmetric situations are considered first and here the simple two noded reduced integration element is used. Numerical results for the stretch forming and deep drawing of circular sheets are presented and comparison with experimental results is made. The second part of the paper deals with the deformation of sheets of arbitrary shape. The general viscous shell element is derived from the standard reduced integration, “thick shell element. Numerical results for simple 3-D sheet forming problems are given.     

The theory of shell structures Aims and methods

This paper discusses in a general way some aspects of the theory of shell structures, and the nature of the theory itself. It emphasises the importance of the interaction between bending and stretching effects in shells, and shows that the “two surface” model of shells provides a useful way of investigating this interaction at both the conceptual and the computational level. A cylindrical shell under various simple kinds of loading demonstrates how the key dimensionless groups emerge from this type of analysis.Some fresh light is thrown on the famous controversy between Love and Rayleigh on the vibration of simple shells. Various problems which arise in the numerical computation of shell structures are discussed. The paper concludes with some general remarks.     

An investigation on enhancing ceramic shell properties using naturally available additives

The ceramic shell properties are very crucial in investment casting (IC) process. Colloidal silica based ceramic shells usually lack sufficient shell properties which causes shell cracking. Sometimes minor repairs can make up the shells. However, every time shell repairing may not be feasible which causes loss to the manufacturer. In the present work, an investigation has been made to improve the properties of colloidal silica based IC ceramic shell by addition of naturally available products such as saw dust and coconut fibres into the ceramic slurries. The important shell properties tested were shell thickness, green and fired strengths, porosity and permeability. The properties of saw dust and coconut fibre modified shells were compared with that of conventional ceramic shell using statistical analysis and it was found that the new shells were better than the conventional shell in terms of shell properties. Further, it was found that the aluminium alloy casting obtained from new shells showed comparatively increase in tensile strength and reduced porosity with that obtained from the conventional ceramic shell. The adopted method proved effective in reducing both production lead time and cost of manufacturing the qualitative IC ceramic shells.