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1.
板料形状、压料筋的设置对汽车覆盖件成形中起皱和未充分拉深的影响 总被引:9,自引:0,他引:9
在汽车覆盖件成形工艺中,无论是对外观还是对功能的要求,起皱和未充分拉深问题是不允许出现的,因此对起皱和未充分拉深问题的预测和防止显得非常重要的。采用数值模拟技术可以在模具设计初期预测产品的几何形状,从而优化工艺参数以便获得高质量的成品。文章以eta/DYNAFORM有限元分析软件为平台,采用弹-塑性有限元法对DDQS钢进行数值模拟,得出相应的FLD曲线、起皱和未充分拉深区域。重点探讨了板料形状和压料筋的设置对起皱和未充分拉深区域的影响,得出了较好的解决方案。 相似文献
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变压边力拉深的原理及实验系统 总被引:27,自引:6,他引:21
板料拉深过程中,压边力是一种重要的工艺参数。由于其在冲压拉深过程中的重要作用及在生产中易于调节、控制,近年来一些汽车工业较为发达的国家,正在进行着变压边力拉深新工艺方法的研究。本文从板料冲压拉深过程对压边力需求的分析中,提出了变压边力控制方法的原理,建立了变压边力拉深实验系统,并以圆锥形件为研究对象对拉深过程中合理的变压边力控制问题进行了探索性研究,取得了阶段性成果。 相似文献
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Jae C Choi Byung M Kim Hae Y Cho Chul Kim 《International Journal of Machine Tools and Manufacture》1998,38(8):931-963
This paper describes the development of a computer-aided design of blanking and piercing for irregular-shaped sheet metal products and stator and rotor parts. An approach to the compact and practical CAD system is based on the knowledge-based rules. Knowledge for the CAD system is formulated from plasticity theories, experimental results and the empirical knowledge of field experts. The system has been written in AutoLISP on the AutoCAD with a personal computer and is composed of six main modules, which are input and shape treatment, production feasibility check, blank layout, strip layout, die layout, and drawing edit module. Based on knowledge-based rules, the system, STRTDES, is designed by considering several factors, such as complexities of blank geometry and punch profile, availability of press equipment and standard parts, utilization ratio which minimizes the scrap in a single or a pairwise operation, bridge width, grain orientation and design requirements which maximize the strength of the part when subsequent bending is involved. Therefore, this system can carry out a die design for each process which is obtained from the results of an automated blank layout drawing with the best utilization ratio for the irregular shape of the product, which was successful in the production feasibility check module, and those of an automated strip layout drawing. It can then generate part drawings and the assembly drawing of the die set in graphic form. The developed system provides its efficiency and effectiveness for blank layout, strip layout, and die layout of irregular-shaped sheet metal products and stator and rotor parts. 相似文献
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结合数值模拟与人工神经网络技术研究了汽车内覆盖件承载地板在冲压成形中压边力的预测。将板料模型零件导入到Dynaform中进行网格划分并对其拉深过程进行模拟仿真,结合正交试验获取不同参数条件下最佳压边力的数据样本,然后运用Matlab软件中的GRNN神经网络工具箱对数据进行训练学习,采用训练好的神经网络对板料成形过程中的压边力进行预测,获得了板料拉深过程中的压边力变化曲线。通过预测结果和模拟结果对比,预测误差在10%以内。将预测的曲线对零件模拟仿真,结果显示零件最大减薄率在25%以内,并对板料进行实际冲压验证。结果显示成形效果良好,无起皱、破裂缺陷,符合实际生产的要求,说明GRNN神经网络可以用于零件冲压过程中压边力的预测。 相似文献
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在金属板材的电磁脉冲拉深成形中,采用一种使成形件凸缘部分的材料可以径向流动的方法。形成了一种拉深—胀形特点相结合的成形工艺,可以提高材料的拉深极限。在此基础上通过改变电压和板料直径等工艺参数,可获得更大拉深高度。 相似文献
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Numerical analysis of the potential of deep drawing processes with hydrostatic pressure lubrication 总被引:1,自引:1,他引:0
Deep drawing is one of the most important forming procedures for the economic production of sheet metal components. Especially
for high-volume parts, deep drawing is a very efficient method of fabrication with high utilization of semi-finished parts.
Certainly, conventional deep drawing processes are restricted by forming limits due to part failure during the drawing process.
The process force is one of the most important factors for this restriction. The narrow process window, especially for deep
drawing of light-weight materials, can be extended by reducing the friction forces at the die radius, using hydrostatic pressure
lubrication. After the numerical analysis of the appearing loads of deep drawing processes, the optimal position for the insertion
of pressurized lubricant was identified and the potential of the hydrostatic pressure lubrication was predicted. With experimental
tests, the results of the simulations were approved. Both, the simulations and the experimental tests showed a significant
reduction of the process forces. 相似文献
7.
On the acting pressure in laser deep drawing 总被引:2,自引:1,他引:1
Through the continuing trend of miniaturization new cost efficient and fast methods for processing of small parts are required.
In this paper a non-mechanical process for the forming process of micro deep drawing is presented. This new pulsed laser based
deep drawing process utilizes an initiated plasma shock wave at the target, which forms the sheet. Several pulses can be applied
at one point and therefore high forming degrees can be reached without increasing the energy density. In this article the
pressure of the shock wave is measured and optimized. Furthermore laser deep drawing of samples made out of pure aluminum,
copper and stainless steel sheet metal with thicknesses of 20 and 50 μm are shown. Finally the forming behavior after single
pulses is presented. 相似文献
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为避免冲压过程中多弯角结构引起的零件内部孔形和外部轮廓的边界误差导致级进模技术实施失败,以多弯角车身钣金件为对象,分析了制件的多弯角冲压成形工艺方案,设计了毛坯排样图;其次,应用单工位全工序有限元法(FEM,Finite Element Method),分析了零件的冲压成形过程,验证了冲压工艺参数与工艺方案的可行性;再次,以所设计的毛坯排样图为基础,对多弯角车身钣金件级进模进行结构概要与工序结构设计,设计并制造了1套13工位级进模;最后,进行了实冲试验,试验获得的制件外观质量好、表面光滑、无起皱与破裂等成形性问题,且关键成形部位精度达到了零件图的设计要求。试验表明:所设计的级进模能够满足企业的生产要求,且设计过程是合理的。 相似文献
9.
S. Yossifon D. Messerly E. Kropp R. Shivpuri T. Altan 《International Journal of Machine Tools and Manufacture》1991,31(3)
The goal of the current study is to adapt a servo-motor driven multi-action press for forming of sheet metal parts under precise velocity control and variable blankholding force. The Engineering Research Center for Net Shape Manufacturing [ERC/NSM] has developed a computer controlled multi-action press with two independently driven punches for research in cold forming of complex parts, using physical modeling techniques. Recently, the same press was modified and upgraded for use in sheet metal forming. As a result of its special design and construction, this press is highly controllable and can perform a wide range of sheet metal forming processes. Tests were conducted in order to obtain the actual press characteristics. Axisymmetric deep drawing experiments were performed with 1100-O annealed aluminum material using all three actions of the press. In these preliminary experiments, the crucial role of blankholding force control on final product quality and drawability was established. 相似文献
10.
《CIRP Annals》2022,71(1):225-228
Deep drawing dies are manufactured using metal sheets. Laser metal deposition is used for bonding the sheets and smoothening the edges. The strength and surface finish of the dies are the key challenges. Milling, roller burnishing, and laser treatment are applied as post-processing for improving the surface finish. A semi-analytical model is developed for selecting the sheet combination for sufficient strength. The new rapid prototyping process offers high flexibility for complex die geometries. The evaluation by deep drawing experiments using DC06 and high-strength HC380LA blanks revealed the feasibility of the new manufacturing routes regarding deep drawability and surface finish. 相似文献
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以汽车后围板为对象,运用BP神经网络对其拉深过程中的回弹量进行预测。通过CATIA建立CAD模型,运用Dynaform软件对板料冲压过程进行仿真分析,借助正交试验获取不同参数组合下的回弹数据,并通过试验验证了关键数据的可靠性,建立了4-9-6的3层BP神经网络回弹预测模型。通过对数据样本进行训练学习,控制其预测的精度为0.01,将预测结果与实际测量结果进行对比,显示预测误差最大为5.62%。说明运用BP神经网络可以实现对复杂拉深件成形的回弹预测,可以大量节省仿真预测的时间,对模具的设计具有很好的指导作用。 相似文献
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阶梯盒形件是汽车制造业中的典型零件,但是由于其拉伸成形困难,废品率较高.针对某阶梯盒形件进行了工艺性分析,规划了冲压生产工艺,并利用AutoForm软件对拉伸成形过程进行了仿真模拟,选取板料尺寸、摩擦系数及压边力为研究对象,对比分析了3个参数对拉伸质量的影响规律,最后给出了优化成形质量的建议,对指导实际生产有一定的意义... 相似文献
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Kerim Isik Gregory Gerstein Thomas Schneider Robert Schulte Daniel Rosenbusch Till Clausmeyer Florian Nürnberger Milan Vucetic Sergej Koch Sven Hübner Bernd-Arno Behrens A. Erman Tekkaya Marion Merklein 《Production Engineering》2016,10(1):5-15
Sheet-bulk metal forming processes combine conventional sheet forming processes with bulk forming of sheet semi-finished parts. In these processes the sheets undergo complex forming histories. Due to in- and out-of-plane material flow and large accumulated plastic strains, the conventional failure prediction methods for sheet metal forming such as forming limit curve fall short. As a remedy, damage models can be applied to model damage evolution during those processes. In this study, damage evolution during the production of two different toothed components from DC04 steel is investigated. In both setups, a deep drawn cup is upset to form a circumferential gearing. However, the two final products have different dimensions and forming histories. Due to combined deep drawing and upsetting processes, the material flow on the cup walls is three-dimensional and non-proportional. In this study, the numerical and experimental investigations for those parts are presented and compared. Damage evolution in the process chains is simulated with a Lemaitre damage criterion. Microstructural analysis by scanning electron microscopy is performed in the regions with high mechanical loading. It is observed that the evolution of voids in terms of void volume fraction is strongly dependent on the deformation path. The comparison of simulation results with microstructural data shows that the void volume fraction decreases in the upsetting stage after an initial increase in the drawing stage. Moreover, the concurrent numerical and microstructural analysis provides evidence that the void volume fraction decreases during compression in sheet-bulk metal forming. 相似文献
18.
《Journal of Materials Processing Technology》2014,214(2):217-228
Force-fit integration of piezoceramic fibers in micro-formed structures is a new approach for function integration in structural sheet metal parts. In a first step, a micro-structured surface is formed in a planar semi-finished sheet metal part by micro-impact extrusion. Piezoceramic fibers are then assembled into this micro-structured surface with a small assembly clearance. The fibers and the structured surface of the sheet metal are joined by a forming process. In the next step, the sheet metal with piezoceramic fibres within a locally micro-formed substructure is shaped by deep drawing into a 3D-geometry. In this paper, results of the micro-impact extrusion and the joining by forming experiments are presented. Furthermore, the design constraints for assembly and joining due to the dimensional and form deviations of the piezoceramic fibers are discussed. Results of a numerical study of micro-forming, joining by forming and the global loading during a deep drawing process step were in good agreement with the experimental investigations. The direct comparison between experiment and numerical simulation increases the process knowledge and shows further improvement potential. 相似文献
19.
Adaptive FEM simulation for prediction of variable blank holder force in conical cup drawing 总被引:14,自引:0,他引:14
Z. Q. Sheng S. Jirathearanat T. Altan 《International Journal of Machine Tools and Manufacture》2004,44(5):487-494
Fracture and wrinkling are two primary failure modes in deep drawing of sheet metal parts. Previous studies showed that properly selected variable blank holder force (BHF) profile, i.e. variation of BHF with punch stroke, can eliminate these failures to draw deeper parts. In this study, an adaptive simulation strategy was developed to adjust the magnitude of the BHF continuously during the simulation process. Thus, a BHF profile is predicted in a single process simulation run and the computation time is reduced. The proposed strategy has been applied successfully to two conical cup drawing operations. The predictions have been compared with experiments and the results indicate that the adaptive simulation strategy can also be used to improve the drawing process for forming non-symmetric parts. 相似文献
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1 INTRODUCTIONInrecentyears ,withtherapiddevelopmentofcomputersoftwareandhardware ,andtheintersectionandcombinationofcomputertechnology ,graphics ,mechanicsandprocessengineering ,thecomputeraid edengineering(CAE)technologybasedonnumericalsimulationhasbeenwidelyappliedinthesheetmetalformingfield[1,2 ] .Nevertheless ,untilnow ,thenu mericalsimulationisconfinedtosimulatesomebasicmodesofdeformationsuchasbending ,deepdraw ing ,bulgingandflanging .Forthedeformationofcomplexwork pieces ,forexa… 相似文献