CN110465584B - Progressive forming limit test method for mesh plate - Google Patents

Progressive forming limit test method for mesh plate Download PDF

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CN110465584B
CN110465584B CN201910717040.0A CN201910717040A CN110465584B CN 110465584 B CN110465584 B CN 110465584B CN 201910717040 A CN201910717040 A CN 201910717040A CN 110465584 B CN110465584 B CN 110465584B
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variable
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mesh plate
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查光成
郑�硕
王瑶
蒋哲东
冯星宇
查一凡
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Nanjing Institute of Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
    • B21D31/005—Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece

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Abstract

The invention discloses a progressive forming method of mesh plateA limit test method, said method comprising the steps of: 1) establishing a variable-angle conical model, and generating a progressive forming numerical control code according to the model; 2) starting the incremental forming machine tool and inputting a numerical control code; 3) executing the incremental forming numerical control code to start processing the variable-angle conical model, and recording the reading of the X, Z shaft of the machine tool at the moment
Figure DEST_PATH_IMAGE002
And
Figure DEST_PATH_IMAGE004
obtaining three-dimensional space coordinates of a primary fracture point
Figure DEST_PATH_IMAGE006
(ii) a 4) Three-dimensional space coordinates of primary fracture point
Figure 427044DEST_PATH_IMAGE006
Substituting the variable-angle conical model to obtain a forming limit angle
Figure DEST_PATH_IMAGE008
(ii) a The forming limit angle of the mesh plate can be quickly tested by a model
Figure 203239DEST_PATH_IMAGE008
The method has the characteristics of simple and convenient operation, high testing efficiency and good accuracy of the testing result.

Description

Progressive forming limit test method for mesh plate
Technical Field
The invention relates to a progressive forming limit testing method of a mesh plate, and belongs to the technical field of numerical control progressive forming.
Background
The technology introduces the idea of layered manufacturing of a rapid prototype manufacturing technology, disperses a complex three-dimensional model into a plurality of layers along the height direction, and carries out plastic processing on a two-dimensional layer along a contour line by a forming tool head to form the sheet metal layer by layer. The forming method saves expensive die design and manufacturing cost, and realizes the digital and customized production of the sheet metal products.
Due to the special processing mode of incremental forming, as shown in fig. 1, the forming tool head performs thinning and drawing on the original plate material under the action of forming force, the material in the forming area performs shear flow along the axial direction of the workpiece under the action of the tool head, the thickness of the plate material is thinned, and the thinning rule follows the cosine law0cos θ (wherein0The original thickness of the plate, theta is a forming angle, and the theoretical thickness of the position of the forming angle theta) of the plate, the plate is subjected to a forming limit angle theta in the forming processMaxWhen the forming angle theta is larger than thetaMaxThe sheet material will crack.
At present, three methods are mainly used for judging and judging the incremental forming limit of a plate, the first method is an arc groove testing method proposed by Wang et al, the method respectively tests the plane strain unidirectional tensile strain state and the bidirectional tensile strain state of the plate in incremental forming through an arc groove and a cross arc groove to draw an incremental Forming Limit Diagram (FLD), but the method is not suitable for testing the forming limit of the plate because meshes in the plate are violently deformed and even broken in the processing of the arc groove; the second method is that the variable-angle spherical frustum-shaped curved surface model proposed by G.Hussain et al is adopted to measure the forming limit of the sheet material in the incremental forming, as shown in figure 2, the method is generally applied to the incremental forming limit angle theta of the non-porous sheet materialMaxJudging; the third is a polymer plate incremental forming limit angle theta proposed in the patent (CN201644097. X)MaxThe method for testing comprises the steps of taking wrinkling of the high polymer sheet as a sheet failure criterion and providing a testing method. Research shows that the metal mesh plate has mesh deformation and material flow during the incremental forming process, and the incremental forming mechanism and material thickness distribution rule are different from those of common plate, so that the said method may not be used in the incremental forming limit test of metal mesh plate and may be also used in making metal mesh plateThe popularization and application of the incremental forming technology in the processing of the metal mesh plate are reduced.
Different from the traditional metal plate material that the bottom of a manufactured part is broken (the initial breaking position is in the currently processed area), the mesh and the plate material can be deformed when the mesh plate is formed, the breakage is formed by expanding and tearing of microcracks caused by tensile stress between two adjacent holes and is sensitive to the tensile stress, the initial breaking position is often in the middle of the manufactured part (the initial breaking position is in the formed area), and if the variable-angle spherical frustum-shaped curved surface model shown in figure 2 is adopted to measure the forming limit angle theta of the mesh plateMaxBecause the forming angle of the traditional variable-angle spherical-table-shaped curved surface model is continuously improved along with the increase of the processing depth of a workpiece, the effect of the current processing area on the formed area is more and more serious (namely, the tensile stress is more and more large), so that the meshes of the formed area are cracked in advance, and the forming limit angle theta of the mesh plate cannot be calculated through the traditional variable-angle spherical-table-shaped curved surface modelMax. At present, the incremental forming limit test of the metal mesh plate mainly utilizes a plurality of conical models with different angles to approach for measurement for a plurality of times, so that the test efficiency is low, the measured forming limit angle is approximated for a plurality of times, the operation randomness is high, and the result error is large.
Disclosure of Invention
The invention aims to provide a method for testing the incremental forming limit of a mesh plate, which aims to overcome the defects that the testing efficiency is low, the measured forming limit angle is subjected to multiple approximation, the operation randomness is high, and the result error is large in the prior art.
A method of progressive formation limit testing of a mesh plate, the method comprising the steps of:
1) establishing a variable-angle conical model, and generating a progressive forming numerical control code according to the model;
2) starting the incremental forming machine tool and inputting a numerical control code;
3) executing the incremental forming numerical control code to start processing the variable-angle conical model, and recording the reading x of the X, Z axis of the machine tool at the moment0And z0Obtaining the three-dimensional space coordinate P (x) of the primary fracture point0，y0，z0)；
4) The three-dimensional space coordinate P (x) of the primary fracture point0，y0，z0) Substituting the variable-angle conical model to obtain a forming limit angle thetaMax。
Preferably, the step 2 further comprises clamping the mesh plate to be tested on a progressive forming machine, installing a forming tool, and moving the axis X, Y, Z of progressive forming to perform tool setting operation, so that the origin of the initial machining coordinate system is Q (0, 0, h).
Preferably, the establishing of the variable-angle cone model comprises the following steps:
establishing a circle with the diameter d in an XY plane;
respectively establishing leading lines with included angles alpha and beta with the positive direction of the Z axis on two sides of a circle in the XZ plane, wherein the height of the leading lines in the Z axis direction is h;
the varied angle cone model is obtained by sweeping along two guide lines of the same height with a circle of diameter d as a cross-section using a characteristic sweeping operation.
Preferably, the spatial equation of the variable angle cone model is:
Figure BDA0002155783790000031
wherein, alpha and beta are respectively the minimum included angle and the maximum included angle between the variable angle cone model and the positive direction of the Z axis, and
Figure BDA0002155783790000032
β＝β0+10°，
β0the incremental forming limit of the pore-free plate is measured by adopting a variable-angle spherical-table-shaped curved surface model; d is the diameter of the lower opening circle of the variable-angle conical model; (x, y, z) are the spatial coordinates of any point on the variable angle cone model.
Preferably, the constraint condition of the boundary of the spatial equation is: z is equal to 0, h]H is the height of the variable angle cone modelDegree; normal vector of any point on its space curved surface
Figure BDA0002155783790000033
Comprises the following steps:
Figure BDA0002155783790000034
wherein the content of the first and second substances,
Figure BDA0002155783790000035
the forming angle theta of any point on the space curved surface is as follows:
Figure BDA0002155783790000036
Figure BDA0002155783790000037
the partial derivative of a space equation of the variable angle conical surface model in the x direction is obtained;
Figure BDA0002155783790000038
the partial derivative of the space equation of the variable angle conical surface model in the y direction is obtained;
Figure BDA0002155783790000039
the partial derivative of the space equation in the z direction of the variable angle cone model.
Preferably, said primary point of rupture has a three-dimensional spatial coordinate P (x)0，y0，z0) Substituting the normal vector of the space curved surface
Figure BDA00021557837900000310
Calculating a forming limit angle theta according to a calculation formula of the forming angle theta on the spatial curved surfaceMax。
Compared with the prior art, the invention has the following beneficial effects: the invention provides a test model and a test method for the incremental forming limit of a mesh plate, and the mesh plate can be formed at one time at a forming angle theta in an epsilon [ alpha, beta ] by adopting a variable-angle conical model]All the fixed-angle conical models can quickly test the forming of the mesh plate through one modelLimiting angle thetaMaxThe method has the characteristics of simple and convenient operation, high testing efficiency and good accuracy of testing results; in addition, the invention is beneficial to the popularization and the application of the incremental forming technology in the mesh plate processing.
Drawings
FIG. 1 is a schematic view of a forming angle in the background art;
FIG. 2 is a schematic diagram of a spherical frustum-shaped curved surface model with a variable angle in the background art;
FIG. 3 is a schematic view of a variable angle cone model;
FIG. 4 is a three-dimensional schematic diagram of a variable angle cone model.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further described with the specific embodiments.
Referring to fig. 3 to 4, a progressive forming limit testing method of a mesh plate is disclosed, which includes the following steps:
(1) establishing a variable-angle conical model as shown in fig. 3, in three-dimensional modeling software, firstly establishing a circle with the diameter d of 20mm in an XY plane, then respectively establishing guide lines with the included angles alpha of 15 degrees and beta of 75 degrees with the positive direction of a Z axis on two sides of the circle in an XZ plane, wherein the height of the guide lines in the Z axis direction is h of 50mm, then performing sweeping along the two guide lines with the circle with the diameter d of 20mm as a section by using a characteristic sweeping operation to obtain the variable-angle conical model, and generating a progressive forming numerical control code according to the model;
the space equation of the variable angle cone model is as follows: f (x, y, z) ═ x2+y2-tan15°tan75°z2+(tan15°-tan75°)xz-10(tan15°+tan75°)z-100＝0
Wherein, alpha and beta are respectively the minimum included angle and the maximum included angle between the variable angle cone model and the positive direction of the Z axis, and
Figure BDA0002155783790000041
β＝β0+10°，β0for measuring by using variable-angle spherical-table-shaped curved surface modelConsistent with a metal mesh plate), where the forming limit angle beta of the non-porous plate measured by a variable angle spherical frustum-shaped curved surface model is taken065 ° of non-porous Al sheet β; d is the diameter of an opening circle under the variable-angle conical model, wherein d is 20 mm; the spatial equation boundary constraints are as follows: z is equal to 0, h]H is the height of the variable angle cone model, wherein h is 50 mm; (x, y, z) are the spatial coordinates of any point on the variable angle cone model.
Normal vector of any point on its space curved surface
Figure BDA0002155783790000051
Comprises the following steps:
Figure BDA0002155783790000052
wherein the content of the first and second substances,
Figure BDA0002155783790000053
the forming angle theta of any point on the space curved surface is as follows:
Figure BDA0002155783790000054
Figure BDA0002155783790000055
the partial derivative of a space equation of the variable angle conical surface model in the x direction is obtained;
Figure BDA0002155783790000056
the partial derivative of the space equation of the variable angle conical surface model in the y direction is obtained;
Figure BDA0002155783790000057
the partial derivative of the space equation in the z direction of the variable angle cone model.
(2) Starting the incremental forming machine tool, clamping the metal mesh Al plate to be tested on the incremental forming machine tool, wherein the installation diameter is
Figure BDA0002155783790000058
Moving a X, Y, Z shaft of the machine tool to perform tool setting operation, so that the original point of an initial machining coordinate system is Q (0, 0, 50), and inputting the incremental forming numerical control code generated in the step (1) into a control system of the incremental forming machine tool;
(3) executing the numerical control code of progressive forming to start machining the variable-angle conical model, stopping machining immediately when the metal mesh Al plate workpiece is broken for the first time, moving the tool head to the breaking point, and recording the reading x of the shaft X, Z of the machine tool at the moment0And z0And (3) substituting the space equation of the variable-angle cone model in the step (1), and obtaining a three-dimensional space coordinate P (x) of the initial breaking point of the mesh plate as shown in FIG. 40，y0，z0)；
(4) The initial breaking point P (x) of the mesh plate in the step (3)0，y0，z0) Substituting the normal vector of any point on the space curved surface in the step (1)
Figure BDA0002155783790000061
And the forming limit angle theta of the metal mesh plate can be obtained by a calculation formula of the forming angle theta of any point on the space curved surfaceMax。
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.

Claims (5)

1. A method for testing the incremental forming limit of a mesh plate is characterized by comprising the following steps:
1) establishing a variable-angle conical model, and generating a progressive forming numerical control code according to the model;
2) starting the incremental forming machine tool and inputting a numerical control code;
3) executing the incremental forming numerical control code to start processing the variable-angle conical model, and recording the resultReadings of machine tool X, Z axes
Figure DEST_PATH_IMAGE001
And
Figure 737753DEST_PATH_IMAGE002
obtaining three-dimensional space coordinates of a primary fracture point
Figure DEST_PATH_IMAGE003
；
4) Three-dimensional space coordinates of primary fracture point
Figure 208048DEST_PATH_IMAGE003
Substituting the variable-angle conical model to obtain a forming limit angle
Figure 328320DEST_PATH_IMAGE004
；
The method for establishing the variable-angle cone model comprises the following steps:
establishing a circle with the diameter d in an XY plane;
in the XZ plane, the included angles between the two sides of the circle and the positive direction of the Z axis are respectively established
Figure DEST_PATH_IMAGE005
A guide wire having a wire height h in the Z-axis direction;
the varied angle cone model is obtained by sweeping along two guide lines of the same height with a circle of diameter d as a cross-section using a characteristic sweeping operation.
2. The method for testing the limit of incremental forming of a mesh plate according to claim 1, wherein the step 2 further comprises clamping the mesh plate to be tested on a incremental forming machine, installing a forming tool, and moving an axis X, Y, Z of incremental forming to perform tool setting operation so that the origin of the initial processing coordinate system is Q (0, 0, h).
3. The method of claim 1, wherein the space equation of the variable angle cone model is:
Figure DEST_PATH_IMAGE007
wherein the content of the first and second substances,
Figure 623297DEST_PATH_IMAGE008
respectively the minimum included angle and the maximum included angle of the variable angle cone model and the positive direction of the Z axis, and
Figure DEST_PATH_IMAGE009
，
Figure 819924DEST_PATH_IMAGE010
the incremental forming limit of the pore-free plate is measured by adopting a variable-angle spherical-table-shaped curved surface model;
Figure DEST_PATH_IMAGE011
the diameter of the lower opening circle of the variable angle conical model; (x, y, z) are the spatial coordinates of any point on the variable angle cone model.
4. A method as claimed in claim 3, wherein the constraints of the spatial equation boundary are:
Figure 230045DEST_PATH_IMAGE012
，
Figure DEST_PATH_IMAGE013
the height of the variable angle conical model; normal vector of any point on its space curved surface
Figure 858735DEST_PATH_IMAGE014
Comprises the following steps:
Figure 116541DEST_PATH_IMAGE016
wherein the content of the first and second substances,
Figure DEST_PATH_IMAGE017
(ii) a The forming angle of any point on the space curved surface
Figure 936598DEST_PATH_IMAGE018
Comprises the following steps:
Figure 912644DEST_PATH_IMAGE020
；
Figure DEST_PATH_IMAGE021
the partial derivative of a space equation of the variable angle conical surface model in the x direction is obtained;
Figure 79446DEST_PATH_IMAGE022
the partial derivative of the space equation of the variable angle conical surface model in the y direction is obtained;
Figure DEST_PATH_IMAGE023
the partial derivative of the space equation in the z direction of the variable angle cone model.
5. A method of testing the progressive forming limit of a mesh plate as claimed in claim 4 wherein the primary failure point is in three dimensional space coordinates
Figure 926179DEST_PATH_IMAGE003
Substituting the normal vector of the space curved surface
Figure 182717DEST_PATH_IMAGE014
And forming angle on spatial curved surface
Figure 646059DEST_PATH_IMAGE018
Calculating the forming limit angle
Figure 141851DEST_PATH_IMAGE004
。
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