数值模拟技术在金属成形过程中的应用

金属成形过程非常复杂,不能像常规机械设计那样进行比较精确的设计计算.现代制造业对塑性成形工艺分析和模具设计方面的高要求使得数值模拟技术在这一领域得到了广泛的应用.通过在计算机上描述整个挤压成形过程,计算分析成形过程中影响较大的一些因素,通过逐步修改逼近过程,以检查模具设计是否合理,以避免起皱、充填不满、自由边变形不合要求等缺陷.通过图象终端对分析结果及影响因素进行反复修改,以趋近最佳结果.最终达到代替或部分代替试验工作,提高设计效率和产品质量,节约资源以及人力、物力的目的.     

有限元数值模拟技术在油箱体成形中的应用

应用Dynaform冲压模拟软件对油箱体的拉深成形过程进行了详尽的有限元模拟分析，找出了油箱体拉深成形过程中的缺陷，并提出了相应的改进方案。结果表明，采用Dymform软件分析油箱体得到的结果与实际冲压过程完全一致。     

快速车轮成形过程的刚塑性有限元数值模拟

采用刚塑性有限元模拟软件TFOMR2模拟了915KKD快速车轮的预成形过程。通过分析车轮预成形过程的塑性流动规律和镦粗压下量对预成形的影响，预测了预成形后毛坯充填模膛的情况，并得到了较佳的镦粗压下量值，为车轮成形工艺设计提供了科学依据。     

粉末体成形的有限元数值模拟

根据粉末体材料的塑性理论,利用体积可压缩有限元法,对粉末体材料成形过程和致密化过程进行了数值模拟,并开发了粉末体材料成形有限元数值模拟分析系统ＰＭ－２ＤＦ．通过对粉末体镦粗过程的有限元数值模拟,说明了粉末体材料在镦粗过程的变形特性、致密化规律及粉末质点的流动规律,并与实验结果进行了对比。     

齿轮精锻成形三维弹塑性有限元数值模拟

用三维大变形弹塑性有限元法对齿轮冷精锻成形过程进行了数值模拟，对以闭式模锻为预锻和以闭式模锻、孔分流及约束分流为终锻的两步成形模式的变形流动情况进行了数值模拟分析。数值分析结果及工艺实验表明在终锻中采取分流，尤其是约束孔分流措施对于降低工作载荷和提高角隅充填能力等方面十分有效。     

一种快速模拟复杂冲压件成形过程的截面分析单元

基于有限变形虚拟功率增量原理的弹塑性大变形有限元理论,建立了两点高效率平面应变板壳单元截面分析模型,并应用非均匀有理Ｂ样条曲线描述模具截面线进行接触判断,能快速获得较理想的板料冲压成形模拟结果。     

有限元模拟技术在板料冲压成形中的应用

应用有限元分析能够成功的模拟出金属板料成形的真实过程 ,进而发现潜在的成形缺陷。作者以Dynaform为工作平台 ,介绍数值模拟技术在板料冲压成形过程中的应用     

LS-DYNA在汽车冲压件成形过程中的应用研究

针对汽车冲压件成形的复杂性,以及在冲压生产过程中易产生的各种质量问题,应用LS-DYNA软件,以汽车冲压件后地板前角封板为研究对象,建立了有限元模型,模拟了该零件的成形过程,最终得出了成形极限图(FLD)和厚度图,成形极限图是判断和评定板料成形性能最为简单和直观的方法,厚度图反映了冲压件在成形后板料厚度的变化,通过这些图的分析,预测了板料的起皱和破裂,为模具设计和生产提供了理论依据.     

有限元-模拟电荷混合法在静电场数值分析中的应用

把有限元和模拟电荷两种数值计算方法组合起来构成有限元－模拟电荷混合法,并运用此方法对静电场进行计算,有限元－模拟电荷混合法能充分发挥两种方法各自的优点,弥补各自的缺点,从理论上推导出了有限元－模拟电荷混合法的系数矩阵和矩阵方程,并以一个实际电场结构主计算对象,采用有限元－模拟电荷法对其静电场分布进行了数值分析,结果表明这一方法的采用对于解决具有多种介质无界场域的电场计算问题是非常有利的,并且可获得较谪的计算精度。     

板料成形过程数值模拟中的接触分析

根据板料成形过程中模具的运动特点,提出了全局搜索和局搜索的接触点搜索算法。建立了接触点的局部坐标系,并对特殊情况进行了适当处理,保证计算的连续性,建立了接触力学模型,分别采用罚函地和修正的库仑摩擦计算接触法向力和摩擦力,保证了接触计算的稳定性。     

对称零件多向挤压工艺有限元仿真

通过三维软件pro/E软件进行建模,以.iges格式把曲面信息导入MSC—Superform中进行有限元分析,根据零件的对称性,取轴对称零件的四分之一进行多向复合挤压成形过程分析,通过两种多向复合挤压不同挤压方案的等效应变云图,确定其较佳的工艺成形方案.该研究为此类多腔零件的挤压工艺提供了有价值的参考依据.     

Numerical simulation method for weld line development in micro injection molding process

In order to reduce the “trial-mold” risk and cost, numerical simulation method was applied to micro injection molding weld line development investigation. The micro tensile specimen which has the size of 0.1 mm (depth)×0.4 mm (width)×12 mm(length) in test area was selected as the objective part, and polypropylene (PP) as the experimental material. Respectively with specific commercial software (Mold Flow?) and general computational fluid dynamic (CFD) software (Comsol? Multiphysics), the simulation experiments for development of weld line in micro injection molding process were executed and the real comparison experiments were also carried out. The results show that during micro injection molding process, the specific commercial software for normal injection molding process is not valid to describe the micro flow process, the shape of flow front in micro cavity flowing which is important in weld line developing study and the contact angle due to surface tension are not able to be simulated. In order to improve the simulation results for micro weld line development, the general CFD software, which is more flexible in user defining function, is applied. The results show better effects in describing micro fluid flow behavior. As a conclusion, as for weld line forming process, the numerical simulation method can give a characteristic analysis results for processing parameters optimizing in micro injection molding process; but for both kinds of softwares quantitative analysis cannot be obtained unless the boundary condition and micro fluid mathematic model are improved in the future.     

Elastic-plastic finite element simulation for diamond turning process

Diamondturningprocessischaracterizedbyhigh dimensionalaccuracyandgoodsurfaceintegrityandhasbeenappliedinmanyadvancedindustrialfields,such ascomputer,automobile,opticsmanufacturing,etc.Usingthistechnology,thesoftmetal,suchasalumi numorcopperoritsalloys,can…     

汽车保险杠树脂传递模塑工艺充模过程的数值模拟

首先建立了汽车保险杠树脂传递模塑充模过程的三维数学模型;然后利用有限元/控制体积法对该模型进行了数值模拟,并对树脂在模腔内的流动进行了表述;最后优化出该成型工艺的最佳工艺条件:前期注射压力设定在0.4 MPa以下,后期注射压力设定为0.6—0.8MPa,合理树脂黏度为0.15 Pa.s左右。采用该工艺条件可有效降低制件的气泡缺陷。     

管材绕弯成形有限元数值模拟

薄壁管数控绕弯精确成形技术是管材生产的重要手段之一．它是一个多因素耦合交互作用的复杂力学过程,在加工过程中存在着截面畸变、壁厚变化等多个工艺问题,会严重影响管材的成形精度和生产效率．对管材绕弯成形过程进行了有限元数值模拟,并通过与理论解和实验结果的对比,验证了有限元仿真过程的正确性,可为生产实际及后续工艺参数的优化提供可靠的技术依据。     

有限元数值模拟法在裂缝性油气藏中的应用

裂缝性油气藏产量占世界石油天然气产量的一半以上,是21世纪石油增储上产的重要领域。有限元数值模拟法是对储层构造裂缝进行定量预测并确定其空间分布的一种有效方法。依据有限元数值模拟法的原理、实现过程和应用实例,对四川盆地裂缝性储层的构造裂缝进行了预测,并用该方法对天然气勘探有利区块进行了评价,对指导海相天然气勘探取得了较好的效果。     

Comparison of rheological analytic model with numerical simulation in powder injection molding filling process

Mathematical model of filling disk-shaped mold cavity in steady state was studied.And the mathematical model under vibration field was developed from the model in steady state.According to the model of filling disk-shaped mold cavity in steady state,the filling time,the distribution of velocity field and the pressure field were obtained.The analysis results from rheological analytic model were compared with the numerical simulation results using Moldflow software in the powder injection molding filling process.Through the comparison,it is found that it is unreasonable to neglect the influence of temperature when calculated the pressure changing with the time at the cavity gate,while it can be neglected in other situations such as calculating the distribution of the velocity fields.This provides a theoretical reference for the establishment of correct model both in steady state and under vibration force field in the future.     

Numerical Simulation of Phenolic Sheet Molding Compound in Compression Molding

1　IntroductionPhenolicsheetmoldingcompound (SMC)isanewindustrialproductwithahighperformancethathasbeenknownformanyyearsforitsexcellentfireresistanceandrelativelylowcost.Theseoutstandingpropertieshaveledittobeingwidelyusedinmanyindustrialdepartments ,suchasbuildingandtransportationdepartments ,etc .Es peciallyinrecentyears ,withtheeverdevelopingdemandoffireresistantmaterials ,thestudyandapplicationofthephenolicsheetmoldingcompoundhavereceivedmoreandmoreattentionintheworld .Thenumericalsimula…     

钢筋弯曲过程的有限元模拟

本文针对钢筋在弯曲过程中的大变形及非线性的特点,运用有限元分析软件ANSYS/LS-DYNA建立了钢筋弯箍系统的有限元模型,对钢筋的弯曲过程进行了数值模拟,并分析了钢筋在不同时刻的弯曲应力变化情况。当钢筋弯曲角度接近于零时,钢筋产生的最大应力发生在与弯箍转套接触部位;随着时间的增大,与箍筋模接触部位的应力迅速增大,且应力最大值逐渐由钢筋的边缘部位向中心部位靠近。     

Three-dimensional finite element analysis of process-induced residual stress in resin transfer molding process

A three-dimensional finite element analysis of process-induced residual stress in resin transfer molding （RTM） process is presented. The finite element method （FEM） was employed to solve the coupled equations involved in the transient heat transfer and the cure kinetics of the resin, and the distributions of internal temperature and cure degree of the composite at any instant time were obtained. The self-consistent field micromechanics model was used to predict the cure-dependent mechanical properties of the composites. Thermal expansion and cure shrinkage were included in the analysis. The thermo-elastic mechanical governing equations were solved using the incremental stress-strain relationship based FEM and the residual stress development was predicted. The present results were validated by the comparisons with the pertinent literature. The numerical example of a half cylinder was presented. The results show that it is necessary to carry out the three-dimensional analysis due to the complex distributions of temperatures, cure degrees and process-induced stress for thick parts, which can be predicted at any point within composite structures in the present analysis.