激光复合织构焊管轧辊模具成形有限元模拟与试验研究

目的提高焊管成形质量,为激光复合织构轧辊模具产业化提供试验依据。方法通过数值模拟方法模拟焊管轧辊成形过程,获得不同摩擦系数组合下板料成形应力应变和径向厚度数据,并获得最优模具表面织构方案,为轧辊模具表面织构处理提供依据。依据数值模拟结果,运用激光表面织构技术对辊子模具表面进行复合织构加工处理,开展激光复合织构模具和未织构模具成形对比,并对成形件进行残余应力、应变、边缘减薄率等检测分析。结果数值模拟结果表明,下辊边缘区域应为减摩区,上辊边缘区域应为增摩区;应对下辊边缘区域进行激光微织构减摩,上辊边缘区域进行激光毛化增摩。成形试验结果表明,试验结果与数值模拟结果基本一致;与未织构模具相比,激光复合织构焊管轧辊模具优化了成形件的应力应变分布,降低了板厚边缘减薄率(5.06%),提高了成形件的均匀性(3.9%),成形件边缘区域形成了残余压应力。结论激光复合织构焊管轧辊模具相比未织构模具,可显著改善成形件的边缘稳定度和成形质量。

Finite Element Simulation and Experiment on the Forming of Laser Composite Textured Roll

The work aims to improve the roll forming quality in order to provide test basis for the industrialization of laser composite textured roll. The roll forming process was simulated by the numerical simulation method to obtain the forming stress-strain and radial thickness of sheet at different friction coefficient combinations and the optimum mold surface texture to provide basis for treatment of roll texture. According to the results of numerical simulation, laser surface texturing was adopted to treat the roller surface, the forming contrast experiment was carried out for laser texturing mold and non-laser texturing mold and the residual stress, strain and edge thinning rate of the forming part were detected and analyzed. From the results of numerical simulation, the edge area of lower roll should be anti-friction area and the edge area of upper roll should be friction-added area. Laser microtexture anti-friction was conducted to the lower roll edge area and laser texturing friction addition was carried out to the upper roll edge area. Through the results of forming test, the test results were basically consistent with the numerical simulation results. Compared to the non-textured mould, the laser surface texturing roll mould could optimize the distribution of molding stress and strain, reduce the thinning rate of the plate thickness by 5.06% and improve the uniformity of the forming part improved by 3.9%. Therefore, the edge area of the forming part was accumulated with residual stress and strain. Compared with the non-textured mould, the laser composite textured roll can obviously improve the edge stability and forming quality of the forming part.