大直径薄壁钛管加热弯曲成形的数值模拟

采用有限元软件ANSYS对大直径薄壁钛管加热弯曲成形过程进行了有限元模拟.利用ANSYS的参数化设计语言APDL分别建立了管件加热过程有限元模型和管件弯曲过程有限元模型,使所做的模拟能较方便地适用于不同的管子外径、弯曲半径以及模具尺寸.研究结果表明,加热温度对薄壁钛管弯曲成形质量有着显著的影响,加热温度在650～700℃之间时管子弯曲成形质量较好.     

大直径薄壁弯管回弹的有限元模拟

以大直径薄壁导管数控弯曲为研究对象,依据实际过程建立了成形以及回弹过程描述方法.在此基础上,应用ANSYS有限元软件,完成了大直径薄壁钛管加热弯曲回弹有限元建模,基于静力隐式算法,实现了大直径薄壁管件热弯成形过程以及回弹的有限元模拟,通过回弹的数值模拟结果与试验的对比分析,验证了本文所建立的模拟方法的有效性.     

ANSYS在激光焊接温度场数值模拟中的应用

通过分析和总结激光焊接过程有限元模拟的研究现状，综述了利用ANSYS进行激光焊接三维温度场有限元数值模拟中，物理模型的建立和网格划分、边界条件、等离子体及熔池对流等问题的处理。     

薄壁钛管差温剪切弯曲热力耦合有限元模型

基于ABAQUS软件环境下的动力显式热力耦合分析模块,建立了TA2薄壁钛管差温剪切弯曲过程模拟三维弹塑性热力耦合有限元模型,讨论了材料模型、热边界条件、单元类型和尺寸、质量放大等有限元建模关键问题,实验验证了有限元模型的可靠性.结果表明:(1)从有限元模型计算的精度和效率考虑,质量放大因子为10000是合理的;(2)单元尺寸越小,热力耦合实体单元模拟管材直线段传力区的温度越低,单元尺寸≤1.0 mm× 1.0 mm的热力耦合壳单元模拟管材温度场的分布达到稳定;(3)与热力耦合实体单元相比,采用1.0 mm ×1.0 mm热力耦合壳单元模拟的管材厚向应变分布更接近于实验结果.     

不确定因素下薄壁铝合金管弯曲的多目标连续稳健优化设计（英文）

结合实验设计和三维弹塑性有限元,在确定性优化设计基础上,提出了不确定因素下薄壁铝合金管数控弯曲的多目标连续稳健优化方法。基于部分析因设计,获得了显著的噪声因子,包括管材性能变化、管材几何尺寸波动和管材-模具摩擦波动。采用田口内外表试验法,考虑主要弯曲成形缺陷,对薄壁铝管数控弯曲芯模直径、芯棒伸出量和助推速度进行了稳健优化设计。通过分别考虑摩擦接触条件、管材料参数和管材几何参数的波动,实现了薄壁铝管数控弯曲芯模直径的稳健性优化设计;通过考虑材料参数波动、芯模与管间的摩擦波动以及芯模直径的制造偏差,实现了芯棒伸出量和助推速度的稳健性优化设计。     

薄壁方形管件激光焊数值模拟

建立了薄壁方形管件模型,筛选出小热输入焊接工艺参数,校核了激光焊双椭球热源模型参数,利用有限元数值模拟软件模拟其焊接过程,研究了约束工装对薄壁方形管件激光焊接温度、残余应力与变形的影响。结果表明:薄壁方形管件激光焊过程中,约束工装下,焊缝及焊缝附近处在小于300℃区间的冷却速度高,焊缝处残余应力比自由焊接时稍大,但焊缝法向上降低速度更平缓,焊接后焊缝面残余变形由2.14 mm减小至0.2 mm,侧面变形由0.32 mm减小至0,焊缝长度方向弯曲幅度由0.8 mm减小至0.26 mm。     

金属板材激光弯曲成形应力应变场的数值模拟

采用有限元对激光弯曲成形过程中应力应变场的过程进行了模拟，分析了弯曲成形过程中钢板上下表面弹塑性变形的变化规律及激光工艺参数对成形的影响。模拟结果与实验结果基本一致。     

中厚船舶钢板激光弯曲成形几何效应的数值模拟

建立板材激光弯曲的三维非线性准静态弹塑性热力耦合有限元模型。使用有限元软件 MSC Marc对中厚船舶钢板的激光弯曲成形过程进行数值模拟。计算了船舶钢板激光弯曲成形过程的温度场和变形场, 并进行相应的实验验证。模拟结果与实验结果吻合较好。用建立的模型对中厚船舶钢板的激光弯曲成形过程中钢板的几何效应进行数值模拟, 讨论了一定工艺条件下钢板几何参数与弯曲角度之间的关系, 为在将来实际生产中制定和优化钢板激光弯曲成形的工艺参数提供理论依据。     

薄壁不锈钢管件滚弯成形工艺有限元分析

应用ANSYS有限元分析软件中的LS-DYNA求解器,对薄壁不锈钢管件弯曲成形过程进行了弹塑性数值模拟.通过对管件弯曲角度试验结果与模拟值的对比分析,证明了建立管件有限元模型的正确性.在此基础上分析了管件滚弯过程的应力、应变,揭示了其成形时的塑性变形流动规律及其对管件质量的影响.结果表明,薄壁不锈钢管件弯曲冷成形的主要失效形式是内侧部分的起皱和外侧部分的失稳.     

薄壁纯钛管数控弯曲成形性能研究

研究了薄壁纯钛(CP-Ti)管在不同弯曲半径和不同材料性能下的多缺陷约束数控弯曲成形性能,通过显式/隐式三维有限元模型和实验研究了先进轻量化材料CP-Ti的成形潜力。结果表明:管材的硬化指数、厚向异性指数和杨氏模量的变化对弯曲成形性能有很大影响;与壁厚减薄和截面畸变相比,失稳起皱是抑制大直径薄壁CP-Ti管弯曲成形性能的主要缺陷。升高温度可以提高CP-Ti管的弯曲成形性能,特别是抗起皱性能。     

Experimental and numerical modeling of buckling instability of laser sheet forming

New experimental results show that laser bending can be extended to generate a bending angle not only towards but also away from the laser beam, giving more flexibility to the process. In order to explain this buckling instability, a series of experiments have been carried out with real-time measurement of the bending angle for different materials, thicknesses, scanning speeds, laser beam diameters and laser powers, pre-bending conditions, and cooling conditions. Furthermore, a 3-D FEM simulation has been performed that includes a non-linear, transient, indirect coupled, thermal–structural analysis accounting for the nonlinear geometric and material properties. The buckling deformation, bending angle and distribution of stress–strain and temperature, as well as residual stresses, have been obtained from the simulations. The bending angle is affected by the temperature distribution and gradient, the mechanical and thermal properties of the sheet metal material, and the process parameters, such as the laser power, the laser beam diameter, the scanning speed, the material, the sample geometry, and other bending conditions. The buckling mechanism can be illustrated by the simulation results.     

Computer simulation and experimental investigation of sheet metal bending using laser beam scanning

Computer simulation and experimental investigation of the sheet metal bending into a V-shape by the laser beam scanning without an external force exerted onto it have been performed. A 3-D FEM simulation has been carried out, which includes a non-linear transient indirect coupled thermal-structural analysis accounting for the temperature dependency of the thermal and mechanical properties of the materials. The bending angle, distribution of stress–strain, temperature and residual stresses have been obtained from the simulations. The sheet metal bending had been performed for different materials, thicknesses, scanning speeds and laser powers. The measurement of real-time temperature and bending angle was carried out. The bending angle is affected by the mechanical and thermal properties of the sheet metal material, the process parameters, and the output of laser energy. The bending angle is increased with the number of laser beam scanning passes and is the function of the laser power and the laser beam scanning speed. The simulation results are in agreement with the experimental results.     

薄壁管材激光弯曲过程热力耦合有限元分析

管材激光弯曲是一种柔性金属塑性加工方法,特别适合薄壁管材弯曲。文章对大径厚比薄壁管材的激光弯曲过程进行热力耦合有限元分析,建立了管材激光弯曲热力耦合有限元分析模型,并进行实验验证。对于薄壁管材激光弯曲,弯曲内侧局部凸起现象较为严重,激光光斑尺寸对凸起程度有一定影响,但不显著。     

Numerical and experimental study on in-plane bending of microchannel aluminum flat tube

Microchannel aluminum flat tubes have attracted more and more attention in recent years, especially in ACR (air conditioning and refrigeration) industry. Rotary-draw bending is a versatile and precise method in forming of tubes. Compared with traditional out-of-plane bending method, in-plane bending can cause different forming defects. During the process, wall thinning, sectional distortion, wrinkling, and channel shape degradation are the main defects that affect tube quality in industrial applications. In this paper, an experimental apparatus for flat tube in-plane bending is manufactured, and experiments are performed to examine the forming quality of tubes. Considering the characteristics of the bending process, based on the LS-DYNA software environment, a 3D elastic–plastic finite element model is established and validated by experiment. Using the validated FE model, the forming quality of microchannel flat tube bending process is evaluated quantitively. Furthermore, the influence mechanism of process parameters, such as bending radius, tool–tube clearance, and channel diameter, has been revealed. The results indicate that the degradation of the tube channels is relatively small under common process conditions; bending radius is the main factor which influences the forming quality of the flat tube; the tool–tube clearance mainly affects the wrinkling of the flat tubes; channel diameter has little effect on the formability of tube.     

循环旋转弯曲变形中65Cu–35Zn黄铜管显微组织和力学性能的演变（英文）

为了细化65Cu-35Zn黄铜管的晶粒尺寸,并改善其力学性能,进行不同变形条件下的循环旋转弯曲(CRB)实验。利用光学显微镜、EBSD和常温拉伸实验,对变形后管材的显微组织和轴向力学性能进行研究。为了获得变形过程中黄铜管的累计有效塑性应变,对黄铜管不同变形条件下的CRB进行有限元模拟。结果表明,常温变形条件下,黄铜管的平均晶粒尺寸随旋转时间的增加而减小;在200℃变形条件下,其平均晶粒尺寸随弯曲角度的减小而减小。随着累计有效塑性应变的增加,变形后黄铜管平均晶粒尺寸减小率呈现增大趋势,其抗拉强度呈现波状增加,而伸长率呈现先增加后迅速减小的趋势。     

内压对薄壁管充液压弯时的影响

失稳起皱和截面畸变是薄壁管弯曲成形过程中的主要缺陷,通过数值模拟和实验的方法,研究了液压支承下管材的弯曲变形行为,进行了从无内压到内压为18MPa的管材充液弯曲成形,分析了充液弯曲成形过程中的内压值对成形的影响,给出了成形后的不圆度和典型点壁厚减薄率的变化规律,结果显示,随着充液压力的增加,管材的截面不圆度逐渐减小,管材内侧壁厚增厚趋势减小,外侧壁厚减薄趋势增大。并根据模拟结果给出了成形后的典型点的应力状态。     

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。     

Φ3～Φ5 mm薄壁细管的矫直工艺参数

斜辊矫直作为管材生产的最后一道工序,为达到薄壁细管严苛的精度要求,最优矫直工艺参数的设定至关重要。为解决薄壁细管矫直的难点,以现有的十辊矫直机为基础,设计了十辊薄壁细管矫直的模型,并进行了工艺参数研究。利用有限元软件ABAQUS建立了薄壁细管材矫直的有限元模型,通过分析不同条件下矫直后管材的X、Y方向的直线偏差、径向偏差得出了适合薄壁细管的最佳压弯量及压扁量,以此拟合出公式。根据公式计算了两组不同情况下管材的工艺参数,通过仿真模拟及实验验证了公式的可靠性,为薄壁细管精密矫直机的开发制造提供了理论依据。     

Effects of process parameters on numerical control bending process for large diameter thin-walled aluminum alloy tubes

Numerical control(NC) bending experiments with different process parameters were carried out for 5052O aluminum alloy tubes with outer diameter of 70 mm, wall thickness of 1.5 mm, and centerline bending radius of 105 mm. And the effects of process parameters on tube wall thinning and cross section distortion were investigated. Meanwhile, acceptable bending of the 5052O aluminum tubes was accomplished based on the above experiments. The results show that the effects of process parameters on bending process for large diameter thin-walled aluminum alloy tubes are similar to those for small diameter thin-walled tubes, but the forming quality of the large diameter thin-walled aluminum alloy tubes is much more sensitive to the process parameters and thus it is more difficult to form.