| 引用本文: | 曹建国,阮康,王雪松,程姣姣,刘江,赵荣国.邻角精确控制的异型管辊弯成形过程数值模拟[J].哈尔滨工业大学学报,2023,55(1):98.DOI:10.11918/202205069 |
| CAO Jianguo,RUAN Kang,WANG Xuesong,CHENG Jiaojiao,LIU Jiang,ZHAO Rongguo.Numerical simulation of special-shaped tube roll forming process based on precise control of adjacent angles[J].Journal of Harbin Institute of Technology,2023,55(1):98.DOI:10.11918/202205069 |
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| 邻角精确控制的异型管辊弯成形过程数值模拟 |
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曹建国1,2,3,4,阮康1,2,3,4,王雪松1,3,4,程姣姣1,3,4,刘江1,2,3,4,赵荣国5
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(1.北京科技大学 机械工程学院,北京 100083;2.北京科技大学 顺德创新学院,广东 佛山 528399; 3.北京科技大学 人工智能研究院,北京 100083; 4.北京科技大学 国家板带生产先进装备工程技术研究中心,北京 100083; 5.江苏帝尔保机械有限公司,江苏 扬州 225000)
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| 摘要: |
| 针对汽车立柱用P形异型管多道次辊弯成形存在相邻凹凸角度偏差大、难以满足角度高精度要求的问题,基于弹塑性大变形理论,应用辊弯成形专业设计软件COPRA建立了P形异型管15道次辊弯成形有限元模型。结合实际生产过程,开展了完整成形过程的有限元仿真,分析发现焊管周长来料不足及P形异型管角部在轧辊孔型内金属流动不均、成形不到位是导致相邻凹凸角角度偏差过大的主要原因。结合仿真结果和生产实际,提出了选择合适的压缩系数、分配恰当的截面变形量和修正轧辊辊形三者相结合的邻角精确控制方法。应用所提方法进行了P形异型管辊弯成形有限元仿真,结果表明:仿真最终产品截面与设计截面基本一致,凹凸角的角度分别为90.5°和89.9°,角度偏差均在±1°的误差范围内；异型管辊弯成形金属流动到位,使得角部金属充满轧辊孔型,可改善P形异型管相邻凹凸角的成形质量。利用所提方法通过辊弯成形工业应用,获得了符合要求的P形异型管,其相邻凹凸角度精度分别提高了33.84%和36.70%,有效改善了P形异型管成形质量,可为生产实践提供依据。 |
| 关键词: 异型管 辊弯成形 轧辊 成形工艺 有限元分析 |
| DOI：10.11918/202205069 |
| 分类号:TG335.4 |
| 文献标识码:A |
| 基金项目:国家科技重大专项(2019ZX06002001-004); 佛山市人民政府科技创新专项(BK22BE019); 国家科技部创新方法工作专项(2016IM010300); 佛山市高校教师特色创新研究项目(2021DZXX20) |
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| Numerical simulation of special-shaped tube roll forming process based on precise control of adjacent angles |
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CAO Jianguo1,2,3,4,RUAN Kang1,2,3,4,WANG Xuesong1,3,4,CHENG Jiaojiao1,3,4,LIU Jiang1,2,3,4,ZHAO Rongguo5
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(1. School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China; 2. Shunde Innovation School, University of Science and Technology Beijing, Foshan 528399, Guangdong, China; 3. Institute of Artificial Intelligence, University of Science and Technology Beijing, Beijing 100083, China; 4. National Engineering Research Center of Flat Rolling Equipment, University of Science and Technology Beijing, Beijing 100083, China; 5. Jiangsu Durable Machinery Co., Ltd., Yangzhou 225000, Jiangsu, China)
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| Abstract: |
| The large deviation of adjacent concave and convex angles in multi-pass roll forming of P-shaped special-shaped tubes for automobile columns cannot meet the high-precision requirements. On the basis of the large elastic-plastic deformation theory, a 15-pass roll forming finite element model of P-shaped special-shaped tube was established by using the professional design software COPRA. Combined with the actual production process, the finite element simulation of the complete forming process was carried out, and it was found that the insufficient supply of the perimeter of the welded pipe and the uneven metal flow of the corners of the P-shaped special-shaped tube in the roll pass caused the large deviation of the adjacent concave and convex angles. Thus, a precise control method of adjacent angles was proposed based on simulation and production practice, which combines selecting the appropriate compression coefficient, assigning the appropriate section deformation, and correcting the roll shape. The finite element simulation of roll forming of the P-shaped special-shaped tube was carried out by the proposed method. Results showed that the cross-section of the simulated final product was basically the same as the design cross-section, the concave and convex angles were 90.5° and 89.9°, and the angle deviation was within the error range of ±1°. The metal flow was in place, so that the corner metal filled the roll pass, which improved the forming quality of the adjacent concave and convex angles of the P-shaped special-shaped tube. The proposed method achieved an increase of 33.84% and 36.70% in the accuracy of the adjacent concave and convex angles of the P-shaped special-shaped tube through industrial application, which can effectively improve the forming quality of the P-shaped special-shaped tube and provide basis for production practice. |
| Key words: special-shaped tube roll forming roll forming process finite element analysis |
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