基于实体单元的薄板成形模拟

传统有限元分析薄板成形一般使用壳单元进行模拟,忽略薄板沿厚度方向应力应变的变化,这很难反映薄板弯曲变形部分的状况.基于连续介质力学及有限变形理论,借助于计算机仿真技术,利用LS-DYNA软件中的实体单元模拟了低碳钢板深冲成筒形件的过程,得到了薄板在冲压成形过程中的应力应变场,并分析了板料各区域的受力变形情况,发现了凸凹模圆角处薄板沿厚度方向的应力应变分布并不均匀,这些模拟结果对筒形工件的深冲压加工具有一定的指导意义.     

深圳网蓝通用科技有限公司

正Since1996日本市场占有率领先的钣金冲压CAE仿真软件www.jstamp-nv.com基于JSTAMP/NV与MatPara的精确回弹预测解决方案\背景当前技术挑战:汽车车身轻量化的需求导致高强度钢板和铝合金车身广泛应用的发展趋势高强度钢板和铝合金钢板成型的回弹预测与控制困难,需要提高有限元仿真的精度     

铝合金整体壁板填料滚弯成型有限元仿真

提出整体壁板填料滚弯成型工艺,建立填料滚弯成型过程的有限元模型.仿真分析填料和工艺参数对滚弯成型壁板的等效应力、剪切应力、等效应变和回弹等的影响规律.结果表明：壁板滚弯成型时纵向筋条的等效应力和应变最大,填料填充滚弯提高壁板等效应力和塑性应变的均匀性,改善壁板弯曲半径的均匀性,提高弯曲件的几何精度;随着压下量的增大,壁板回弹率减小.     

基片式FBG在飞机蒙皮测试中的对称补偿研究

基片式FBG传感器封装结构在应变测试中受到广泛关注,尤其是在航空航天领域,其粘贴方式对监测飞机蒙皮应变具有重要意义。为了提高基片式封装结构的FBG测量飞机蒙皮应变精度,对薄板试验件粘贴基片式FBG传感器进行力学性能研究,实验结果表明传统粘结基片式FBG传感器方式会引起被测薄板材在拉伸过程中产生非线性变形。据此,通过ANSYS有限元分析软件仿真粘贴1 mm传感单元的1.5 mm薄板静态加载过程,并进行静力学有限元优化分析,力学分析及理论推导结果显示,对称粘贴基片式FBG传感单元能够解决应变与波长非线性关系,且能够有效补偿温度对测量的影响。搭建FBG解调系统与MTS力学测试实验系统,实验结果表明,在对称补偿的布点方式下,应变测试线性度为0.998,传感单元应变灵敏度为0.946 pm/με,提高了应变测试精度,可以有效的应用到飞机蒙皮应变测试。     

基于JSTAMP/NV的中厚板冲压回弹分析

由于中厚板在冲压成型过程中的应力分布特点与常规薄板冲压有所不同,因此以JSTAMP/NV提供的解决方案为例,探讨中厚板回弹分析中单元类型和材料模型等关键参数的设定.利用JSTAMP/NV提供的解决方案对料厚为7 mm的某铁路货车梁进行回弹仿真,并使用专用于中厚板回弹分析的参数设定,结果表明仿真结果与试验结果吻合良好。     

基于JSTAMP/NV的厚板弯曲件回弹分析要点

以铁路货车某类零件为例,结合铁路货车冲压件的特点,从建立回弹分析的数学模型入手,用JSTAMP/NV研究回弹的有限元求解过程,找出影响回弹的主要因素.结合实际模具设计,从坯料的网格划分、成型速度和自适应设置等方面论述提高回弹仿真分析精度的若干要点.     

电池盒的多工步冲压仿真

针对多工步冲压过程中材料的流动和应力 应变的分布规律相当复杂,用解析方法描述难度较大的问题,采用DYNAFORM对电池盒的6步深拉深冲压过程进行数值模拟仿真.仿真结果与试验结果的对比分析验证有限元仿真模型的正确性,说明数值仿真技术与试验相结合方法可以有效解决该问题.     

基于计算机仿真技术的薄板冲压成型毛坯形状和尺寸反算

以计算机仿真技术为基础，提出了一个新的方法，解决了薄板冲压成型过程中毛坯状形状和尺寸反算的一些关键问题。有限元仿真能很好地模拟材料的流动，具体体现在网格上节点的移动，根据某种映射，确定不同时时刻下单元中点的位置变化以及不同时刻位置变化之间的联系，从而能获知初始毛坯中哪些部分参与了零件成型，并最终获得优化的毛坯形状和尺寸。用一个方形盒冲压实例验证了本方法的正确性和快速性。     

基于防御节点法的板料成型仿真分析

研究汽车覆盖薄板冲压成型问题,针对各种压力精度和稳定性要求在板料成型的接触力计算中,传统采用的计算方法有罚函数法和拉格朗日乘子法.由于拉格朗日乘子法与显式算法不相容,所以大多采用罚函数法计算接触力.但是罚函数法计算不稳定,罚参数难以确定.为了保证精度,提出将防御节点法用于板料成型中的接触外力计算.防御节点法是一种既能精确计算接触力,又能采用拉格朗日乘子法使约束条件得到精确满足,可避免求解联立方程组的算法.并使用编写的计算机程序进行仿真.通过与罚函数法相比较,结果验证了防御节点法是一种高精度的接触力计算方法,可为设计提供依据.     

薄板冲压成型过程计算机仿真中板料起板料起皱的预测

针对薄板冲压成型中起皱这一常见的材料失效形式,借助于计算机仿真技术,利用板料压缩失稳理论和有限元计算方法,搜索计算得到反映板料各处发生起皱难易程度的屈曲临界因子,生成起皱云图来观察材料各部分的稳定状态,观测可能出现起皱的部位,为修改冲压工艺和修模提供依据,通过分析起皱云图得出的结论与实验结果非常接近。     

Development of parallel explicit finite element sheet forming simulation system based on GPU architecture

Sheet forming simulation is very important for vehicle body design. Due to the increase of complexity and scale of the CAE model, a tradeoff between the accuracy and efficiency become the bottleneck for application. Therefore, a parallel explicit finite element (FE) based on graphics processing unit (GPU) architecture for sheet forming is developed. Implementation details with computer unified device architecture (CUDA) are considered in this work. A pre-index strategy is suggested for parallelization of nodal force assembling. Parallel reduction method is introduced to calculation of the global time step. To ensure the reliability and accuracy of the GPU-based program, double precision floating and intrinsic functions are implemented for the explicit FE computing. The simulation results based on a commercial NVIDIA GTX285 device can obtain about 27X speedup than on a Intel Q8200 CPU, which demonstrates the efficiency of the parallel sheet forming simulation system.     

基于有限元逆算法的压边力优化

依据理想形变理论，研究开发了冲压成形过程模拟的有限元逆算法，实现了计算机程序，并利用有限元逆算法，以变形后工件中厚度分布误差为目标函数，对冲压过程中的压边力进行优化。通过实例证明了逆算法及基于逆算法的冲压工艺参数优化方法的有效性。     

Mesh parameterization based on one-step inverse forming

A novel planar mesh parameterization algorithm via flattening or unfolding is proposed by introducing a so-called one-step inverse approach (IA) based on physical plastic deformation of metal materials. As opposed to methods based on geometric idea, the algorithm is more suitable for CAD models, e.g. rapid prediction of blank shape in sheet metal forming for auto-body panels. Benefiting from proper pre-processing steps, rapid simulation of sheet metal forming and optimal initial solution guess, the proposed algorithm flattens meshes onto a plane with lower area distortion and minimizes the angular distortion. Some numerical examples of results generated by the new parameterization method are provided, and the corresponding analyses are given as well, such as distributions of strain, stress, thickness distribution and formability, etc.     

板料成形模拟后处理中的截面物理量的显示技术*

在自行开发的板料成形有限元后置处理系统FASTAMP_POST中,采用了动态获取截面物理量的算法,实现了截面物理量实时显示功能。该功能真实反映了网格物理量的大小及其变化趋势,具有原理简单、易实现、执行速度快的优点。     

Porting an industrial sheet metal forming code to a distributed memory parallel computer

The parallel version of the sheet metal forming semi-implicit finite element code ITAS3D has been developed using the domain decomposition method and direct solution methods at both subdomain and interface levels. IBM Message Passing Library is used for data communication between tasks of the parallel code. Solutions of some sheet metal forming problems on IBM SP2 computer show that the adopted DDM algorithm with the direct solver provides acceptable parallel efficiency using a moderate number of processors. The speedup 6.7 is achieved for the problem with 20000 degrees-of-freedom on the 8-processor configuration.     

Interactive-adaptive geometrically nonlinear analysis of shell structures

This paper presents an investigation of interactive-adaptive techniques for nonlinear finite element structural analysis. In particular, effective methods leading to reliable automated, finite element solutions of nonlinear shell problems are of primary interest here. This includes automated adaptive nonlinear solution procedures based on error estimation and adaptive step length control, reliable finite elements that account for finite deformations and finite rotations, three-dimensional finite element modeling, and an easy-to-use, easy-to-learn graphical user interface with three-dimensional graphics. A computational environment, which interactively couples a comprehensive geometric modeler, an automatic three-dimensional mesh generator and an advanced nonlinear finite element analysis program with real-time computer graphics and animation tools, is presented. Three examples illustrate the merit and potential of the approaches adopted here and confirm the feasibility of developing fully automated computer aided engineering environments.     

Optimal process design of sheet metal forming for minimum springback via an integrated neural network evolutionary algorithm

The process of sheet metal forming is characterized by various process parameters. Accurate prediction of springback is essential for the design of tools used in sheet metal forming operations. In this paper, an evolutionary algorithm is presented that is capable of handling single/multiobjective, unconstrained and constrained formulations of optimal process design problems. To illustrate the use of the algorithm, a relatively simple springback minimization problem (hemispherical cup-drawing) is solved in this paper, and complete formulations of the algorithm are provided to deal with the constraints and multiple objectives. The algorithm is capable of generating multiple optimal solutions in a single run. The evolutionary algorithm is combined with the finite element method for springback computation, in order to arrive at the set of optimal process parameters. To reduce the computational time required by the evolutionary algorithm due to actual springback computations via the finite element method, a neural network model is developed and integrated within the evolutionary algorithm as an approximator. The results clearly show the viability of the use of the evolutionary algorithm and the use of approximators to derive optimal process parameters for metal forming operations.     

A robust and accurate geometric model for automated design of drawbeads in sheet metal forming

A robust and accurate geometric model of real drawbeads that can be used for the automated design of drawbeads is presented in the paper. A three-dimensional geometric drawbead is a lofted surface, of which the section curves are constructed parallel to the stamping direction on the control points. Adaptive control point interpolation is introduced to simplify the management of the drawbead geometry and avoid unexpected shapes. Given primitive control points on a drawbead curve, dominant control points are adaptively obtained with the shapes of both the drawbead curve and the binder considered. An a priori heuristic parameter adjustment strategy is proposed to correct the parameter errors of section curves, which improves the accuracy and consistency of the drawbead geometry. By incorporating the proposed geometric drawbead with a previously developed intelligent drawbead optimization algorithm, a fully automated design process for drawbeads is realized that includes geometric modeling, finite element analysis, intelligent optimization of the drawbead geometry, and die manufacturing. Finally, a fender example is presented to verify the feasibility and validity of the fully automated drawbead design process. The simulation results with the optimized geometric drawbeads and equivalent drawbeads are compared with the experimental results. The proposed geometric drawbead shows remarkable practicability and accuracy in the automated design of drawbeads in sheet metal forming and demonstrates good consistency with the experimental results while the equivalent drawbead model introduces unneglectable deviations.     

应用Two-Stage方法的薄板零件定位策略优化设计

针对当前柔性薄板夹具定位策略优化需要大量的有限元分析,限制了夹具设计的效率和质量的问题,为了减少有限元分析的次数,提出一种基于Two-Stage方法的夹具定位方案设计方法.该方法以刚体模型为基础,应用粒子群算法进行三定位点优化,再建立基于径向基函数的响应面模型优化其他定位点.通过尾灯支架板实例对文中方法进行优化的结果表明,其具有良好的模拟效果和较高的预测精度.     

One point quadrature shell elements for sheet metal forming analysis

Summary Numerical simulation of sheet metal forming processes is overviewed in this work. Accurate and efficient elements, material modelling and contact procedures are three major considerations for a reliable numerical analysis of plastic forming processes. Two new quadrilaterals with reduced integration scheme are introduced for shell analysis in order to improve computational efficiency without sacryfying accuracy: the first one is formulated for plane stress condition and the second designed to include through-thickness effects with the consideration of the normal stress along thickness direction. Barlat’s yield criterion, which was reported to be adequate to model anisotropy of aluminum alloy sheets, is used together with a multi-stage return mapping method to account for plastic anisotropy of the rolled sheet. A brief revision of contact algorithms is included, specially the computational aspects related to their numerical implementation within sheet metal forming context. Various examples are given to demonstrate the accuracy and robustness of the proposed formulations.