超高强钢前纵梁零件冲压开裂分析与处理

目的解决780 MPa级别超强度钢板冷冲压生产汽车前纵梁时发生的冲压开裂问题。方法通过网格应变分析技术和仿真分析,研究该零件冲压开裂的原因,分析引起开裂的因素,基于CAE模型系统,研究压边力、模具间隙、坯料尺寸、材料性能对开裂的影响规律。结果降低压边力和增加模具间隙均能减轻开裂,但是无法消除冲压开裂;坯料尺寸缩小可以消除冲压开裂,但是优化坯料尺寸需要改变模具上的坯料定位器,同时增大起皱风险;通过提升材料性能可以消除开裂。结论考虑最终各方案成本,选择性能优异的材料进行生产,将冲压开裂率降低至0.6%,满足了冲压要求。     

Touran轿车天窗框架冲压成形的数值模拟

应用LS-DYNA有限元软件,对Touran轿车天窗框架冲压成形过程进行了数值仿真,研究了框架易于失效沟槽处材料的变形行为,并预测了开裂产生的原因,同时对其成形后的厚度变化、变形安全裕度及天窗框架的材料选择进行了分析.仿真结果与实际冲压结果取得了较好的一致,证明了所建立的天窗框架仿真模型的合理性及计算结果的准确性,同时也进一步说明了材料性能对成形化具有显著的影响,为天窗框架冲压材料的选择提供了科学依据.     

600 MPa级元宝梁用钢冲压开裂原因分析

为解决元宝梁冲压开裂问题,用OM和SEM等仪器与ABAQUS有限元仿真软件对600 MPa级元宝梁用钢冲压开裂原因进行了分析.结果表明:600 MPa级元宝梁用钢化学成分、力学性能与冷弯性能均满足标准要求,金相组织为准多边形铁素体与少量珠光体的混合组织,不存在带状组织;开裂件断口形貌呈现出明显鱼骨状形貌,钢板中心分层,两侧分布起源于中心分层并沿同一方向扩展的三角形台阶状断口,不同形貌断口均属于韧性断裂,而断口整体形貌显示材料在断裂前没有发生缩颈过程.利用ABAQUS软件对"先冲压再压边工艺"与"先压边再冲压工艺"两种工况进行有限元分析,结果显示:先冲压再压边工艺边部应力集中更严重,边部节点应力超过了材料抗拉强度从而导致撕裂现象的发生;由"先冲压再压边工艺"改为"先压边再冲压工艺"后元宝梁冲压开裂率由50%降至0,材料边部变形均匀,未见缩颈与开裂现象发生.     

铝锌硅镀层的冲压性能

铝锌硅镀层(Galvalume)作为钢铁基体的热浸镀材料,具有良好的耐腐蚀能力,但是Galvalume镀层在受力变形时容易出现裂纹。针对热浸镀Galvalume镀层成形开裂问题,通过对不同镀层厚度(重量)镀铝锌板进行冲压试验和180°弯曲试验,观察裂纹源的产生。采用扫描电镜(SEM)和能谱(EDS)对镀层及中间过渡层进行研究,分析影响镀层冲压开裂的原因。结果显示:镀层的重量(厚度)是影响其冲压开裂的主要原因,随着镀层厚度的下降,镀层外侧受拉应力作用开裂趋势变小;开裂位置显示主要元素为Fe、Al、Si元素,变形过程中Galvalume合金过渡层相对于镀层更容易开裂;Galvalume合金过渡层的厚度是影响Galvalume冲压开裂的主要原因,随着合金过渡层厚度的降低,过渡层开裂趋势变小。     

汽车立柱加强板成形分析

目的轻量化是汽车零部件设计的发展方向,汽车立柱因需要在碰撞中承受外力而变形,并为其他零件提供足够强度和刚度的安装点,一般都使用高强钢材料制造,以达到轻量化的要求。方法对采用DP590高强钢制造的典型结构汽车B柱加强板进行了工艺分析,以提出高强钢立柱加强板零件的设计及成形工艺优化方案。通过AutoForm软件的板料仿真技术,对采用590DP高强钢的典型汽车B柱加强板的冲压工艺进行了数值模拟分析。结果成功预测了板料成形过程中可能存在的起皱、开裂等问题。结论分析结果为汽车立柱加强板冲压工艺提出了改进方案,实现了模具的设计及优化。     

火灾下钢筋混凝土简支板力学响应机理

拉力膜理论针对的是板大变形下开裂状态的研究,对于火灾下板发生大变形尚未开裂的机理缺乏合理的解释。为此该文采用合理的材料热工性能和热-力耦合本构关系,应用ABAQUS有限元软件对火灾下钢筋混凝土简支单向板和双向板的温度场和热力耦合场进行了三维实体有限元分析,在实验验证的基础上深入探讨火灾下混凝土和钢筋的应力变化规律以及钢筋混凝土简支板的力学响应机理。分析结果表明：简支板发生了激烈的应力重分布现象,其变形过程经历弹性、弹塑性、塑性以及受拉开裂四个阶段,在弹塑性和塑性阶段板底混凝土双向受压的倒拱效应使得双向板抗火性能优秀;当火灾下钢筋混凝土简支板实验没有达到力学响应的受拉开裂阶段时,板底直接受火区域不会出现开裂现象;与单向板相比,双向板进入塑性与受拉开裂阶段的时间大幅度延长,且塑性与受拉开裂阶段变形速率减缓,因此其抗火性能更优。     

铅锌尾矿砂掺量对静态破碎剂性能影响的实验研究

针对传统静态破碎剂存在"高温喷孔、材料膨胀性能利用率低及成本高"等问题,提出以铅锌尾矿砂作为掺料进行静态破碎剂水化峰值温度、膨胀性能的影响研究。实验结果表明:水化峰值温度分为初始温度发展(初始～45℃±5℃)、快速上升(45℃±5℃～峰值)和缓慢降温(峰值～结束)三个阶段;掺料破碎剂膨胀性能与掺入量成反比,掺量为20%和30%,峰值温度分别下降14.82%、28.15%,膨胀率下降13.08%、16.82%;掺量30%是其重要临界点,超过会引起膨胀性能的断崖式下跌。通过不同掺入比例的混凝土静爆实验发现:掺料量对试件初始开裂时间影响明显,对最终开裂效果影响不大。综合各实验参数,确定20%～30%的掺量最优参数,既保证了开裂效果,又达到了抑制喷孔以及降低成本的目的。     

大型车车身覆盖件冲压成形特征分析及选材研究

为满足大型车身覆盖件冲压成形要求并实现钢板与零件的对路供应,必须在深入解析零件成形特征的基础上,确定高应变部位的成形敏感材料参数.在材料力学性能测试和成形极限分析的基础上,对侧围外板的冲压成形特征和成形敏感参数进行了分析.结果表明:侧围外板零件高应变部位的变形方式为胀形-深拉延变形,n值和r值为影响侧围外板零件成形的主要材料敏感参数.     

激光拼焊侧围加强板用材分析及性能控制技术

目的研究某车型侧围加强板生产稳定性的材料性能。方法通过对某车型激光拼焊侧围加强板的主要用材TRIP800进行分析,研究不同3种生产批次材料性能和组织上的差异性,包括化学成分、显微组织、残余奥氏体含量、扩孔试验、力学性能、表面粗糙度的测量。结果 3种不同批次材料生产后,两种批次满足生产稳定要求,一种批次不能满足稳定生产要求,识别了TRIP800材料影响零件冲压开裂的关键性能指标,主要为材料伸长率及硬化指数。结论针对某侧围加强板的生产稳定性,材料伸长率大于25%,硬化指数n值不低于0.18的情况下,能够满足稳定生产。扩孔试验结果表明,该零件的成形过程中,扩孔率并不是唯一影响开裂的性能指标。     

硼钢板高温拉伸性能研究

高温冲压成形是一种新的成形工艺,它能大幅提高钢板的成形性能。对硼钢板的热冲压成形性能进行了研究,对不同温度和变形速率下的试样进行了拉伸试验,并利用最小二乘法进行多元线性回归,建立了高温状态下的变形抗力数学模型,为钢板的热成形技术研究的开展提供了科学依据。     

Effect of plate separation on restrained burst test

The deformation experienced by a package during an unrestrained burst test is not the same in every case. This deformation will direct the forces resulting from the internal pressure to specific areas depending on the package geometry, the material and the type of seal. It may influence the resulting burst values and the interpretation of the results in general. In recent years, the use of restraining fixtures in the burst test has been suggested by both industry and academic researchers. It is thought that restraining plates can limit the extent and variation of deformation of the package during the burst test. Restrained burst tests, using different plate separations, were performed for pouches and trays. It was found that for both types of packages; the burst pressure is inversely proportional to plate separation. Copyright © 2003 John Wiley & Sons, Ltd.     

钢纤维高强混凝土冲切板的挠度计算

通过钢纤维高强混凝土简支方板的冲切试验,得到冲切板的板面变形分布图及中心点荷载挠度曲线,认为板在冲切破坏之前发生的变形主要是弯曲变形。该变形反映了板在各个受力阶段的抗弯性能,也在很大程度上直接影响着冲切锥面上的应力分布和板的抗冲切能力。对冲切板在破坏前各受力阶段的挠度进行了计算,计算结果与实测曲线吻合良好。     

Computation of thermoelastoplastic stresses in crack problems by the BEM

In the framework of deformation theory and assuming a power hardening material, a 2D elastoplastic crack problem is considered under loading conditions expressed in terms of a stationary temperature field. The HRR stress field is compared with the one obtained by a BEM analysis. It is shown that a three-term asymptotic expansion of stresses leads to a good approximation of the near field. The free coefficient in the asymptotic expansion has to be determined via the BEM results. The analysis is provided for a rectangular plate with a central crack under two kinds of boundary heat conditions. This revised version was published online in August 2006 with corrections to the Cover Date.     

Thermal buckling of various types of FGM sandwich plates

The sinusoidal shear deformation plate theory is used to study the thermal buckling of functionally graded material (FGM) sandwich plates. This theory includes the shear deformation and contains the higher- and first-order shear deformation theories and classical plate theory as special cases. Material properties and thermal expansion coefficient of the sandwich plate faces are assumed to be graded in the thickness direction according to a simple power-law distribution in terms of the volume fractions of the constituents. The core layer is still homogeneous and made of an isotropic material. Several kinds of symmetric sandwich plates are presented. Stability equations of FGM sandwich plates include the thermal effects. The thermal loads are assumed to be uniform, linear and non-linear distribution through-the-thickness. Numerical examples cover the effects of the gradient index, plate aspect ratio, side-to-thickness ratio, loading type and sandwich plate type on the critical buckling for sandwich plates.     

T2铜板冲裁间隙对冲裁力及断面质量的影响

为提高冲裁件的断面质量和冲裁效率,实现对冲裁间隙的合理优化,现提出了一种新的板料冲裁试验构想:采用广泛应用于变压器等领域板厚为6 mm且相同规格的T2紫铜作为试验材料,通过更换凸模来改变冲裁间隙,完成在不同冲裁间隙条件下对板料的冲裁试验,采集并分析冲裁力随冲裁行程的变化曲线;同时测量光亮带的宽度和最大冲裁力位置,并拟合冲裁力、光亮带宽度等与冲裁间隙之间的曲线.试验表明:冲裁力在塑性变形阶段增大幅度先快后慢,而在此阶段的初期冲裁间隙对冲裁力几乎无影响,但随着冲裁的深入,冲裁间隙越大,冲裁力则越小,当进入断裂带后冲裁力急速下降;对比在相同冲裁间隙条件下冲裁力随冲裁行程的变化曲线和断面质量,可获得冲裁件断面光亮带会随着冲裁力达到最大值时而结束.研究表明,当冲裁间隙为16.67%左右时,光亮带宽度较大且冲裁力较小.     

提高纸壳电雷管穿孔能力的有效途径

文章从纸壳电雷管的装药结构、压药密度、药－药接触形式、聚能穴的保护等方面，对铅板穿孔的影响作了一些探讨，对提高雷管的铅板穿孔有一定的实验价值。     

双钢板混凝土组合结构抗冲击性能的研究进展

根据5组33片四边简支双钢板混凝土组合板的试验结果,将组合板的变形模式归纳为弯曲变形模式和冲切变形模式,推导其抗力和刚度的理论计算式,提出能够描述组合板受力全过程的抗力函数模型,并通过现有试验和数值模拟结果验证模型的准确性。基于该模型研究含钢率、材料强度、连接件布置等参数对组合板变形模式和耗能能力的影响,结果表明：含钢率和钢板强度对SC板的极限承载力和耗能能力影响较大,而混凝土强度的影响很小;为了充分利用钢板的力学性能,应合理限制含钢率和钢板强度,或加强连接件布置保证组合作用;不同的设计参数可能导致不同的变形模式和破坏顺序,设计中应针对具体的需求对设计参数加以优化。     

The effect of geometric scale on impact induced fragmentation, and its application to the design of dual plate armor

An analysis is presented which predicts that, for a fixed impact velocity, impact induced fragmentation becomes more severe as geometric scale increases. Test data is presented which supports this prediction, and which allows calculation of material dependent coefficients. The analysis was based on a minimization with respect to radius, for an expanding body, of a total energy density term (expansion kinetic energy per unit volume plus surface energy per unit volume). The test configuration was a steel sphere impacting an aluminum plate, with fragmentation recorded by a stack of spaced witness panels. The tests were run at full and half scale. Correlation between testing and analysis was achieved for the number of fragments perforating the front witness panel when a term analogous to a threshold energy was introduced. While the fragment count showed a dependence on geometric scale, the relative depth of penetration (number of witness panels perforated) did not. This suggested that the targets were fragmented, but that the projectile remained in one piece. A reduction in penetration depth with increasing impact velocity was seen, and was attributed to increased projectile deformation. For cases where the projectile would fragment (for example, if a harder target material were used), the effect of geometric scale on the performance of dual plate armor is predicted by analysis. The prediction is that, for impact velocities where projectile breakup at the outer plate of dual plate armor is a factor, the armor required to stop a large scale projectile can be lighter, on a relative basis, than the armor required to stop a small scale projectile.     

The effects of back plate materials on perfect cone formation in impact-loaded soda-lime glass

In order to investigate the possibility of processing brittle materials by ball impact, the effects of back plate materials on cone crack formation in glass plate by impact with small spheres were evaluated experimentally. Crack morphologies developed in soda-lime glass with back plate materials of Polyurethane, PMMA and Aluminum were investigated as a function of impact velocity. Back plate materials were more effective in producing perfect cones than unbacked glass plates. In the case of PMMA, perfect cone was formed over a larger velocity range. The velocity range over which perfect cones were formed was influenced by both the thickness and the material of the back plates. By the proper selection of back plate materials, the application of this punching process to brittle materials in industrial technology is expected.     

Semi-analytical mechanical and thermal buckling analyses of 2D-FGM circular plates based on the FSDT

In the present paper, mechanical and thermal buckling analyses of two-directional functionally graded material (2D-FGM) circular plate are investigated. The motion equations have been derived based on the first-order shear deformation theory (FSDT) and power series method has been employed to solve the motion equations. Two different kinds of boundary condition including simply supported and fixed are considered. The material properties are assumed to vary in both transverse and radial directions according to power and exponential laws, respectively. Comparisons with available studies in the literature confirm the high accuracy of the current approach. The effects of geometrical parameters and 2D-FG power indices on the critical buckling load have been studied. It is shown that increase of modulus of elasticity of outer layers of plate due to higher presence of hard phase of FGM, in radius and thickness directions of the plate makes it possible to attain a more solid structure against mechanical buckling loads, while increase of coefficient of thermal expansion and coefficient of thermal conduction of outer layers of plate results in less stability against thermal buckling loads.