复杂空间弯管三维自由弯曲成形有限元模拟及试验

目的以一复杂空间弯管为例,开展三维自由弯曲成形实验研究。方法首先提出三维自由弯曲成形工艺解析方法,然后通过有限元模拟与实际试验相结合的方法进行研究。结果有限元模拟所得到的弯管与CAD模型相比,弯曲半径偏差值不超过2%,吻合度较高。实际成形出的弯管与CAD模型对比显示,第1个弯曲段的实际弯曲半径为118 mm,设计值为120 mm,实际值与设计值偏差1.67%;第2个弯曲段的实际弯曲半径为133 mm,设计值为130 mm,实际值与设计值偏差2.30%,2个弯曲半径的偏差值均不超过3%。结论验证了三维自由弯曲成形工艺解析方法的可靠性,有限元模拟较好地指导了实际成形试验。

Simulation and Experimental Study on Three Dimensional Free Bending of Complex Space Elbow

Study on the free bending process taking the forming of a complex space elbow as an example. Firstly, the process analytical method of free bending technology is proposed. Then, conduct the study by combination of finite element simulation and experimental study. Compared with the CAD model, the bending radius deviation of finite element simulation is not more than 2%, and the coincidence degree is very high. Comparison between the actual bent tube and CAD model reveals that: The bending radius of the first bending section is 118 mm while the design value is 120 mm, deviation value between them is 1.67%; The actual bending radius of second bending sections is 133 mm while the design value is 130 mm, deviation value between them is 2.30%. Both of the two deviation values are not more than 3%. Finite element simulation and experimental results verify the reliability of the proposed analytical method; The finite element simulation is a good guide to the actual forming test.