钢丝绳成形力学行为的非线性有限元分析

钢丝绳捻制成形过程属于三维梁大转动弹塑性变形问题.钢丝绳的加工应力不仅影响成形性,而且由其引起的残余应力对钢丝绳结构强度有很大影响.为保证钢丝绳成形模拟计算精度和效率,从而为钢丝绳成形工艺与结构强度的合理设计提供依据,本研究建立了考虑大转动几何非线性和材料非线性的共转坐标系弹塑性有限元计算基本方程,在此基础上编制了钢丝绳成形过程模拟计算程序.通过数值模拟计算分析钢丝绳捻制成形过程的反扭转系数对加工应力应变分布和残余应力的影响,计算结果表明:反扭转系数对捻制成形过程中应力应变和残余应力及形状冻结性有显著影响,合理的反扭转系数应取略大于1.0的值.实验结果证实了本文提出的捻线成形过程数值模拟几何模型和有限元计算模型的有效性.

LARGE ROTATIONAL NONLINEAR FINITE ELEMENT ANALYSIS OF MECHANICAL BEHAVIOR OF WIRE ROPE LAYING

Wire rope laying is an issue of large rotational ellasto-plastic deformation of three-dimensional beam.The formation stress affects the formability of wire rope,and the resultant residual stress greatly affects the structural strength.In order to assure the accuracy and efficiency in the numerical simulation of wire rope laying,and design the laying process parameters and the structural strength reasonably,a finite element method for analyzing the deformation of wire rope laying is proposed.The method takes into account the large rotational geometric non-linearity and the elasto-plastic deformation which involves co-rotational coordinate system.Based on the mentioned method,an algorithm of the laying process simulation of wire rope is developed.The results of analysis clearly indicate that self-rotating ratio greatly affects the distribution of stress and strain under the laying,the residual stress and the shape stability.The reasonable value of self-rotating ratio should be slightly more than 1.0.The geometric model and the numerical simulation method proposed in this paper are also validated by experimental data.