EFFECT OF UNEQUAL DEFORMATION IN DEVELOPMENT OF ADVANCED PLASTIC PROCESSING TECHNOLOGIES

0 INTRODUCTION(Plastic processing technology can make materials shape and improve their properties. Under the situation of rise of international market competition, knowledge economy, and green manufacturing, plastic processing technology is faced with a challenge from mark, information, environment, and resources. Therefore, plastic processing technologies are required to develop towards the 21st century in order to produce parts with light weight, high strength, high precision, high effi…     

DEFORMATION ANALYSIS OF SHEET METAL SINGLE-POINT INCREMENTAL FORMING BY FINITE ELEMENT METHOD SIMULATION

Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.     

Generation and suppression of local severe plastic deformation in sectional multi-point forming

Sectional multi-point forming (SMPF) technology provides a new solution for forming large-size sheet metal. With this technique, large-size parts of sheet metal can be manufactured on a smaller multi-point forming press. But the force status and deformation of the workpiece are complicated in SMPF; the local severe plastic deformation will be produced easily in the transition region, and strain-hardening will be commonly produced subsequently. The hardening is difficult to eliminate in subsequent processes, which will largely affect the final deformation quality. In this paper, the generation of local severe plastic deformation was discussed; NURBS-based modeling method was used to construct the shape of the assortative region to suppress the defect. Experiments proved that the method is fairly effective. Finally, a plan was suggested to raise further the forming limit of materials and enhance the work efficiency by combining multi-point press forming with assortative region method.     

基于ABAQUS的金属切削数值模拟分析

采用ABAQUS有限元软件对切削过程进行了2D和3D数值模拟,分析了切削深度、切削速度等切削工艺参数和刀具前角、刃倾角等刀具几何参数对切削过程的影响;分析过程中考虑切削产生的热量对切削变形的影响,获得了切削应力场、应变场以及温度分布;通过观察和分析切削后表面粗糙度和切屑形状等,为刀具设计和确定工艺参数提供依据。     

Numerical study the flow stress in the machining process

In the machining process, the workpiece is under severe plastic deformation with large strain, high strain rate, and temperature. It is necessary to know the flow stress of workpiece material in such condition to better understand the mechanism of chip formation, tool wear and damage, etc. In this study, a Split Hopkinson Pressure Bar (SHPB) with synchronically assembled heating system was employed to study the flow stress similar to the deformation condition in the machining process. A phenomenological constitutive model was proposed by the regression analysis of the experimental results. Furthermore, orthogonal metal cutting processes were carried out by the finite element method (FEM). The cutting force predicted by the FEM showed good agreement with the experimental results, which confirmed that the proposed constitutive model can give an accurate estimate of the flow stress in the machining process.     

Consideration of geometric nonlinearity in rigid-plastic finite element formulation of continuum elements for large deformation

A rigid—plastic finite element formulation for the continuum elements employing the geometric nonlinearity during an incremental time step is presented. In sheet metal deformation, the displacement for each step is considerably large even though the effective strain increment is very small. For such large displacement problems, geometric nonlinearity must be considered. In the elastic—plastic finite element using continuum elements, general incremental formulations to include the geometric nonlinearity are available. However, in the conventional rigid—plastic finite element analysis using continuum, elements, the geometric nonlinearity has not been considered properly during an incremental time step. In this paper, in order to incorporate geometric nonlinearity to rigid—plastic continuum elements during a step, the convected coordinate system is introduced. To show the stability of strain distributions by the effect of geometric nonlinearity according to incremental step size, two sheet metal forming processes, stretching and deep drawing process, are analysed with various step sizes. Then the computed results using the derived equation are compared with those obtained without considering geometric nonlinearity.     

金属正交切削加工过程的有限元分析

运用大型通用有限元程序对金属正交切削加工过程进行非线性弹塑性有限元模拟分析，得到不同刀具前角在加工过程中对切屑形状、应力分布、应变分布、残余应力及残余变形的影响，得出刀具前角值与剪切角的关系。计算验证了一些实验结果，结论可供工程应用参考。     

金属切削过程中晶体塑性变形的有限元分析

基于金属材料塑性变形理论,利用有限元分析软件,建立了金属切削过程中的晶体变形模型,对二维正交金属切削过程中的晶体塑性变形进行了数值模拟。将仿真结果与实验数据进行了对比,验证了相关理论和模型的有效性。     

大变形成形过程刚塑性无网格伽辽金方法

在非稳态大变形塑性成形过程中，由于节点的大范围移动和流动的非均匀性，导致分析精度下降。针对移动最小二乘近似精度的提高，尤其是边界附近节点分析近似精度的提高，提出了相应的处理方案，以保证分析的精度。通过采用影响域节点控制方法以及边界节点分布密度动态控制方法，实现了塑性成形过程的无网格伽辽金方法的自适应分析。对拉普拉斯方程及典型的大变形成形过程进行了分析，通过与拉普拉斯方程解析解和相应的商品化刚塑性有限元软件Deform的分析结果进行对比，验证了处理方案的正确性。     

运用声发射技术监测金属塑性成型过程中润滑状态的研究

为监测金属塑性成型过程中的润滑状态,采用运用声发射技术,通过对无润滑和有润滑时金属塑性变形过程和摩擦过程的监测及对比,分别研究了金属摩擦声发射信号和塑性变形声发射信号.结果表明,不同材料摩擦产生的声发射信号数值上大小不同,同种材料摩擦声发射信号数值上小于塑性变形声发射信号;采用声发射技术,基于实时波形和声发射信号参数的平均值都能监测金属塑性成型时的润滑状态.     

低频振动塑性成形粘弹塑性模型的体积效应分析

采用Kirchner对应变时间历程的基本假设,针对振动拉伸建立一个一维粘弹塑性模型;利用MATLAB中的符号计算,推导粘弹塑性本构方程的显式表达式.通过确立粘弹塑性边界并对本构方程进行数值求解,可以确定金属在振动加工过程中,其应力应变在粘弹性与粘塑性之间的变化情况.通过计算瞬时应变的大小与屈服限建立粘弹性变形和粘塑性变形的判断准则.在考虑粘弹塑性本构关系中的后继屈服情况、应变历程、应变率历程及弹性应变等因素后,可以确定单轴振动拉伸时材料变形的动态应力和平均应力.根据所给定的振型参数和材料力学性能参数,结合特定的振动拉伸实例,分别得出金属在准静态拉伸和振动拉伸时的动态应力-时间、动态应力-应变和平均应力-应变率的变化趋势等,实现基于粘弹塑性本构关系的低频振动塑性成形的体积效应机理分析.     

含裂纹强度失配焊接接头弹塑性变形分析

采用有限元方法对平面应变条件下含裂纹不同强度失配的平板拉伸焊接接头的弹塑性变形进行了分析,研究了焊缝与母材强度失配系数、焊缝硬化性能、裂纹长度等对接头塑性变形的影响。结果表明：强度失配系数对接头塑性变形有显著影响。低匹配时,变形首先集中在焊缝中,而高匹配则对焊缝起到了一定的保护作用。失配系数一定时,不同焊缝硬化性能接头的塑性变形发展趋势是一致的;但当外载较大时,局部塑性变形程度不同,焊缝的硬化性能降低,裂尖塑性变形增大。
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Simulation of severe plastic deformation by finite element method with spatially fixed elements

A method for simulating large plastic deformation in metal forming processes is proposed. To avoid the difficulties arising from the distortion of elements in the rigid-plastic finite element method, the elements are defined with reference to an unchanging spatial grid rather than the workpiece, so that the elements are not changed by the deformation of material. The monitoring points embedded in the deforming material provide the information of the distortion of grid attached to the material and of distribution of flow stress. The sharp change of flow direction at the corner of tool is treated by the element with a singular point. Axi-symmetric backward extrusion of cans is simulated as an example of a process with severe deformation. The computed grid distortion, distribution of equivalent strain and working load are in good agreement with the experimental ones measured in extrusion of aluminium cans.     

Finite element analysis of planar twist channel angular extrusion (PTCAE) as a novel severe plastic deformation method

A new severe plastic deformation (SPD) method based on equal channel angular pressing (ECAP) is introduced for producing ultrafine grains in bulk alloys, entitled as “Planar twist channel angular extrusion (PTCAE)”. In PTCAE method, there is additional angle, α, (plus φ and ψ angles in ECAP method) which represents angle associated with the lateral reversal arc of curvature in deformation zone. Three dimensional finite element method (FEM) simulations of both ECAP and PTCAE processes were performed in order to investigate the plastic deformation state of processed samples and, moreover, the effect of different die geometry (in terms of variation of planar twist angle) on plastic strain distribution and magnitude. Results revealed that PTCAE process related with ECAP process can impose higher strain values in different shear planes simultaneously in one deformation zone. Therefore, PTCAE can produce UFG or nanostructured materials better than ECAP method which has simpler design and significantly higher efficiency compared with other new SPD processes.     

Practical applications of the “energy–triaxiality” state relationship in metal cutting

Most of the energy spent on metal cutting is due to the unavoidable plastic deformation of the layer being removed during its transformation into the chip. Based on the new principle of metal cutting being a purposeful fracture process, the dominant parameter that controls this process in orthogonal metal cutting (OMC) is the triaxiality state. Therefore, the chip triaxiality state in the deformation zone can be correlated to the energy of the unwanted plastic deformation for a particular cutting configuration. This article investigates this type of correlation by changing the cutting tool geometry. A series of finite element (FE) simulations were performed for various tool rake angles shows a strong relationship between the stress triaxiality state parameter in the deformation zone and the required cutting force components.     

基于变形均匀性的锻造过程微观组织优化方法及其应用

在中国国家自然科学基金项目《锻造成形微观组织优化方法研究及应用》资助下，为提供一种控制锻造成形制品微观晶粒尺寸的理论方法和途径，开展基于变形均匀性的锻造过程微观组织优化研究。 锻造生产除保证产品的基本形状要求外，更重要的是通过材料的塑性变形提高产品的综合机械性能。因此，金属塑性成形过程微观组织模拟与优化研究具有应用价值。 在描述金属在高温塑性变形中组织变化机制基础上，提出材料在热锻成形过程中动态再结晶、静态再结晶，以及晶粒长大等微观组织演变机理。金属塑性变形是以位错运动实现的。随着变形的进行，位错密度不断增加，高位错密度聚集的能量使材料处于不稳定状态。对于低层错能金属(碳钢)的热塑性变形，因其动态恢复缓慢而不能充分消除高密度层错能，动态恢复之后紧接着会出现动态再结晶现象。未能经过动态恢复和动态再结晶充分软化的金属停止变形后，其组织将发生静态再结晶。再结晶过程完成后的新组织是亚稳定的，为获得更稳定的组织，需要释放晶粒内部的潜能。因此，再结晶完成后，要发生进一步的晶粒长大来减少单位体积内的晶界面积。     

多模式超声振动等径角挤压超细晶纯铝成形机理研究

超细晶金属材料由于具有优异的力学性能,特别适合微小金属零件的塑性成形。大塑性变形法是制备超细晶金属材料的常用方法,等径角挤压法被认为是最具有发展前景的大塑性变形方法之一。传统等径角挤压需要通过多道次的应变量累积来获得超细晶材料,制备效率较低。将超声振动与等径角挤压过程相结合可以有效减小挤压成形载荷,提高等径角挤压制备超细晶的性能和效率。现有研究主要采用工具辅助超声振动模式,提出并研发基于工件辅助超声振动模式的等径角挤压成形工艺,并对不同超声振动模式1070纯铝等径角挤压成形机理进行对比研究,研究工具超声振动和工件超声振动两种不同振动方式对晶粒道次细化能力的影响规律。结果表明,随着超声功率的增大,工具超声振动和工件超声振动的超声软化效应逐渐增强,能更大幅度降低等径角挤压成形力,并提高晶粒道次细化能力。工件超声振动比工具超声振动更有利于吸收超声能量,从而能更有效提升超细晶金属的制备效率。     

环形金属密封总成密封机理及性能分析

环形金属密封总成是水下井口头系统重要组成部分,其性能直接影响到水下井口头系统的安全性,甚至整个水下油气系统的可靠性。分析环形金属密封总成的密封机制和工作原理,结合有限元分析结果,从密封环在密封过程中的变形情况来分析其密封性能。结果表明:密封环在弹性变形阶段可以实现密封,但对密封环的表面粗糙度和表面质量有很高的要求,在环形密封总成工况条件下无法保证,应避免在此阶段实现密封;密封环在塑性变形阶段能够填补环表面存在的缺陷,实现良好的密封;在塑性变形阶段,密封环接触面的变形情况成为影响密封性能的唯一因素。     

Finite element simulation of flexible roll forming with supplemented material data and the experimental verification

Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.     

滑移线基本理论及其在金属切削加工中的应用

滑移线理论是一种图形绘制与数值计算相结合的求解平面塑性流动问题的理论方法.应用塑性力学的滑移线理论分析了金属切削过程中变形滑移现象,得到金属切削过程中切削力的一种新的计算方法,给出了切削力的计算公式.这一分析方法和计算公式可较合理地分析计算切削力,对解决工程实际问题有一定的指导意义和应用价值.