金属板材数字化进成形过程数值模拟.pdfVIP

摘 要 金属板料无模渐进成形引入 分层制造 的思想 使用专用的成形工具头沿规划 好的运动轨迹 对金属板料进行无噪音的逐层连续局部塑性加工 获得复杂的壳类零 件 实现了金属板料的柔性加工 由于加工时是对金属板材的局部加压 变形连续积 累而达到整体成形 因此加工的工件精度较高 最重要的是整个过程 从建模到CAE 分析 到加工成形 易于实现自动化 这些特点使得该技术成为一项很有发展前途的 先进制造技术 由于金属板材分层渐进成形的工艺较复杂 各种参数如 加工层距 工具头进退 点的分布及加工轨迹很难用试验的方法确定 如何选择合理的工艺参数来得到理想的 加工工件成为了问题的关键 根据金属板材分层渐进成形为多工步成形的技术特点 提出了金属板材分层渐进成形的有限元模拟方案 本文利用有限元分析软件LS-DYNA 对金属板料渐进成形的过程进行了模拟 根 据试验特点建立了相关的有限元模型 对其中工具头的运动轨迹和加载方式进行了简 化 同时根据试验设备的特点和成形方式建立了边界条件和约束 保证了模拟的真实 性 并据此模型分析了成形过程中板料上的应力 应变分布特点 对一些影响板材成 形质量的关键因素如 加工层距的大小 工具头的进退动作等进行了深入分析 同时 对点支撑形式也作了初步研究 关键词 板材成形 渐进成形 数值模拟 有限元模拟 I Abstract With introducing Layered Manufacture (LM) method into the sheet metal processing, Sheet metal Incremental Forming, which realizes the flexibility of sheet metal forming, processes sheet metal layer by layer with the increments of continuous local plastic forming along the programmed trajectory. The technology can directly manufacture workpieces with the shape of sheet, and the machining precision is very high because the metal plate is pressed only in some parts of the plate and the distortion is accumulated continuously to form whole shape. The importance of the technology is easy automatization during whole process (from modeling to CAE analysis and to machining contour). All of these characteristics make the technology become a advance manufacture technology which has a development future. Since the technology of the metal layered incremental forming process is realitively complicated, and various parameters such as layer depth distributing of leaving and approaching point and process mark are difficult to choose by the experimental methods, it is the key factor for sheet metal digital for