CN102601281A - Method for determining blanks of different thickness for local loading forming of three-dimensional frame-shaped member - Google Patents

Abstract

Disclosed is a method for determining blanks of different thickness for local loading forming of a three-dimensional frame-shaped member. The method includes steps of determining a calculating formula for sizes of inflow ribbed cavity materials according to various loading states in a forming process to realize fast analysis of a simplified interface and shortening time for determining blank shapes, and modifying blank shapes according to numerical simulation results, and determining the blanks of different thickness which meet the filling demands so as to reduce cost. By the method, the determined size distribution of the blanks of different thickness is reasonable, the flaws such as insufficient filling, folding and the like in the forming process are eliminated, machining allowance and forming load are reduced, and the blanking is easy due to the simple blank shapes.

Description

Confirm the not method of uniform thickness blank of three-dimensional frame component local loading and shaping usefulness

Technical field

The hot-working that the present invention relates to the less-deformable alloy in the hot-working field is forged, and specifically is that a kind of definite shaped as frame three-dimensional structure local loading and shaping is used the not method of uniform thickness blank.

Technical background

Adopt the high-performance light alloy material, like titanium alloy, and lightweight structure, like structures such as thin-walled, integral body, band muscle, be Performance And Reliability, the light-weighted effective technical way of realization equipment that improves parts.Large-scale gusset class integrated member with the thin fu jie structure of high muscle has improved structure efficiency effectively, alleviated equipment weight and the military service performance with excellence has been arranged, and is lightweight load-carrying member important in the aerospace flight vehicle.

This type of large complicated member not only be out of shape but also element structure is complicated by the moulding material difficulty, projected area is big, adopts this class A of geometric unitA of traditional plastic forming process monolithic molding to need huge forcing press, generally exceeds the existing equipment ability.Adopt mould subregion realization local loading and combine isothermal forging can effectively reduce shaping load, expansion capacity of equipment.But because projected area is big and complex structure, in its plastic forming process with forming defectses such as folding, that filling is discontented appear easily.Usually flow in order to reduce unhelpful material, blank should approach the forging projection of shape in the floor projection shape.In order to guarantee the die cavity filling, to avoid forming defects, need to change sotck thinkness and distribute simultaneously to obtain preliminary volume distribution.

Because size is big, complex structure and have extreme size mating feature, the forward sunykatuib analysis based on method for numerical simulation of this type of gusset class integrated member forging and molding overall process needs long computing time.The preform optimization design method that employing is simulated based on the inverse analog and the forward of method for numerical simulation is comparatively difficult, and needs long computing time, limit the application of these class methods.For the gusset class A of geometric unitA; General its preform blank shape is similar to finish-forging spare; Often the height of finish-forging spare muscle, wide, radius of corner are carried out scaling and designed preform blank (work such as T. Altan; Lu Suoyi. modern forging---equipment, material and technology [M]. Beijing: National Defense Industry Press, 1982; J.C.Choi, B.M.Kim, S.W.Kim.Computer-aided design of blockers for rib-web type forging [J] .Journal Materials Processing Technology, 1995,54 (1-4): 314-321).The preform blank shape more complicated that adopts above these methods to obtain near the forging shape, is difficult to be applicable to the Plastic Forming of large complicated small lot gusset class integrated member.

For this type of large complicated member, adopting simply not, the uniform thickness blank can reduce cost, effectively improve the die cavity filling.People such as Yang He (Sun Nianguang, poplar is closed, Sun Zhichao. and large titanium alloy bulkhead isothermal closed die forging forming technology is optimized [J]. rare metal and engineering, 2009,38 (7): 1296-1300; Z.C.Sun; H.Yang.Forming quality of titanium alloy large-scale integral components isothermal local loading [J] .The Arabian Journal for Science and Engineering; 2009; 34 (1C): 35-45) divide awkward district and the easy district that is shaped of being shaped with member according to filling effect; According to the material volume of different piece design sotck thinkness, this not the uniform thickness blank improved the die cavity filling, but still have the obvious underfill in subregion.(open meeting, Yao Zekun wears bright Zhang Hui etc.; The Guo Hong town. the physical analogy [J] of metal structure ausforming process metal flow rule and filling property. aero-manufacturing technology; 2007, (1): 73-76,91) the Applied Physics simulation experiment method confirmed the whole not uniform thickness blank shape that forges that loads of titanium alloy gusset class A of geometric unitA at " Z " type interface; But do not consider the local loading characteristic of mould subregion; And long expense of experimental technique cycle is high, particularly for large-scale gusset class integrated member, has limited the application of these class methods.

Zhang Daweis etc. are at Journal Materials Processing Technology the 210th volume; 2 phases; Set up material shunting layer place under the local loading state that the mould subregion causes in the Analysis of local loading forming for titanium-alloy T-shaped components using slab method paper of delivering on the 258-266 page or leaf to the distance calculation formula at muscle die cavity center, following particularly:

Material shunting layer place under under the local loading state that the mould subregion causes to muscle die cavity center apart from x _kAdopt formula (1) to calculate:

$\left\{\begin{array}{cc}{x}_k=\frac{b}{2}& {\mathrm{\σ}}_x{|}_{x=b/2}\≤q\\ x_k=\frac{1}{4}(l+b-\frac{H^2}{\mathrm{mb}})& {\mathrm{\σ}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(1\right)$

Wherein:

${\mathrm{\σ}}_x{|}_{x=b/2}=2K+\frac{\mathrm{mK}}{H}(l-b)$

$q=2K(1+\frac{H}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; H is the loading zone sotck thinkness; M is the normal shearing friction factor; σ _xDo not flow to the stress of blank X-direction in the web district of muscle die cavity for material, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral.

For improving the die cavity filling, adopt not uniform thickness blank.The surface of said not uniform thickness blank is stepped, and the thickness difference of this ladder is Δ H.But formula (1) is not suitable for the calculating at material shunting layer place under the local loading state that is caused by this thickness difference.

For being similar to bulkhead member shown in Figure 4; People such as Zhang Dawei (Zhang Dawei; Poplar is closed, Sun Zhichao, Fan Xiaoguang. the large complicated grand micromodel of gusset class A of geometric unitA local loading ausforming [C]. and the 3rd national precision forging scientific seminar collection of thesis; 3-5 day in December, 2008, Yancheng, Jiangsu: 104-111) point out can see as by frame component 6 and gusset shape member 7 entire combination and form according to such integrated member of architectural feature of member.

The cross section of described frame component 6 is " worker " font; The both sides sidewall is the combination of arc or straight line or arc and straight line; Be distributed with rib between the sidewall of both sides; Distance between the both sides is much smaller than the length of sidewall; According to " Shape Classification method " (work such as T. Altan; Lu Suoyi. modern forging---equipment, material and technology [M]. Beijing: National Defense Industry Press; 1982) this member can be classified as " microscler forging ", and a major dimension of said " microscler forging " is significantly greater than all the other two sizes; The significant rib of depth-width ratio (h/b＞1) is densely distributed, and the rib in the zone is interspersed.

Described gusset shape member is approximate rectangular; According to " Shape Classification method " (work such as T. Altan; Lu Suoyi. modern forging---equipment, material and technology [M]. Beijing: National Defense Industry Press; 1982) this member can be classified as " disk forge piece "; There are two general size to equate in three sizes of said " disk forge piece ", and greater than another size of forging; The distribution of the significant rib of depth-width ratio (h/b＞1) is lax than frame component, and the rib in most of zone distributes along a direction.

People such as Yang He (Sun Nianguang, poplar is closed, Sun Zhichao. and large titanium alloy bulkhead isothermal closed die forging forming technology is optimized [J]. rare metal and engineering, 2009,38 (7): 1296-1300; Z.C.Sun; H.Yang.Forming quality of titanium alloy large-scale integral components isothermal local loading [J] .The Arabian Journal for Science and Engineering; 2009; 34 (1C): 35-45) divide awkward district and the easy district that is shaped of being shaped with member, also correspond respectively to above-mentioned frame component 6 and gusset shape member 7 according to filling effect.

Summary of the invention

Can not be full of for overcoming the perhaps subregion that exists in the prior art; Perhaps do not consider the local loading characteristic of mould subregion; Perhaps the high deficiency of cost the present invention proposes a kind of definite three-dimensional frame component local loading and shaping and uses the not method of uniform thickness blank.

The present invention includes following steps:

Step 1 is confirmed the interface of member; The interface by arc-shaped interface with form and run through two loading zones with the vertical straight line interface two parts of directions X; Described interface is parallel to the center line of member width

Step 2 is simplified the interface of confirming; Determined interface upper surface and lower surface all are distributed with a plurality of ribs symmetrically; Symmetrical center line one side with the member thickness direction is a simplifying interface, and each rib in this simplifying interface is designated as i muscle, i=1～n respectively; The rib of shaping simplifying interface adopts local loading and shaping, and the mould district location is the center of subregion muscle in the loading; Confirm that a rib in the 2nd muscle～n-1 muscle is the subregion muscle;

Step 3 confirms that the simplifying interface place needs not uniform thickness blank shape; Realize confirming that through simplifying interface being carried out rapid analysis the simplifying interface place needs not uniform thickness blank shape; When simplifying interface is done rapid analysis, get one not the uniform thickness blank and confirm the blank shape of simplifying interface according to initial blank as initial blank; Simplifying interface is done in the rapid analysis, three kinds of local loading states and a kind of whole stress state are arranged; Said three kinds of local loading states are respectively; Because first kind of local loading state that mould part load to form, the second kind of local loading state that forms by the different depth of different webs district mould, and the third local loading state that causes by the step-thickness difference Δ H of the not step-like surface existence of uniform thickness blank; Each simplifying interface is being carried out rapid analysis, each muscle die cavity place of whole counterdie to set up local rectangular coordinate system; The Y coordinate of said local rectangular coordinate system is positioned at the symmetrical centre of muscle die cavity width of living in, and the origin of coordinates of each local rectangular coordinate system is positioned at the intersection point place of this Y coordinate and X coordinate;

Simplifying interface is carried out rapid analysis, confirm the blank shape of simplifying interface; Detailed process:

A. confirm shunting layer position and muscle die cavity filler volume calculation formula according to the stress state in the simplifying interface local loading and shaping;

Need not to wait the geometry characteristic of thick stock, mould according to the simplifying interface place, can three kinds of local loading states of appearance and a kind of whole stress state in the local loading and shaping process;

First kind of local loading state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib; Described first kind of local loading state arrives between the branch mould position near the complete muscle die cavity of minute first of mould position in loading zone; Blank in this zone contacts with loading upper die and lower die fully, and stress state that at this moment should the zone is first kind of local loading state;

Under first kind of local loading state; The local loading width is and occurs in first kind of local loading state region near minute complete muscle die cavity of first of mould position center two times to distance between the subregion muscle cavity lateral, and said subregion muscle cavity lateral is the sidewall that first kind of local loading state one side appears in this muscle die cavity; Local loading width l does not change in the stage in local loading, and occurring between the same line journey of sotck thinkness H in first kind of local loading state region is linear relationship; Adopt computing formula (1) calculate first kind of local loading state material shunting layer place down arrive muscle die cavity center apart from x _k:

$\left\{\begin{array}{cc}{x}_k=\frac{b}{2}& {\mathrm{\σ}}_x{|}_{x=b/2}\≤q\\ x_k=\frac{1}{4}(l+b-\frac{H^2}{\mathrm{mb}})& {\mathrm{\σ}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(1\right)$

Wherein:

${\mathrm{\σ}}_x{|}_{x=b/2}=2K+\frac{\mathrm{mK}}{H}(l-b)$

$q=2K(1+\frac{H}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; H is for first kind of local loading state region sotck thinkness occurring; M is the normal shearing friction factor; σ _xDo not flow to the stress of blank X-direction in the web district of muscle die cavity for material, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral; The local coordinate system that is adopted in the formula (1) by blank in the simplifying interface the local coordinate system of inflow muscle die cavity;

Occurring first kind of local loading state region sotck thinkness H in the forming process is confirmed by formula (2) with the relation that loads patrix stroke s:

H＝H ₀-s (2)

In the formula: H ₀For first kind of local loading state region initial blank thickness occurring; S is for loading the patrix stroke;

Flow into the material volume V of muscle die cavity _InConfirm by formula (3):

$V_{\mathrm{in}}={\∫}_{s_1}^{s_2}{x}_k\left(s\right)\mathrm{ds}---\left(3\right)$

Flow into the material volume V of subregion muscle die cavity _OutConfirm by formula (4):

$V_{\mathrm{out}}={\∫}_{s_1}^{s_2}[\frac{l}{2}-x_k\left(s\right)]\mathrm{ds}---\left(4\right)$

Second kind of local loading state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib; The both sides web thickness of muscle changes; In loading and shaping; Blank between the adjacent muscle die cavity with a side of this muscle die cavity contacts with loading upper die and lower die fully; And the blank between the adjacent muscle die cavity with opposite side of said this muscle die cavity does not contact with loading upper die and lower die fully, and the stress state between the adjacent muscle die cavity with a said side of said this muscle die cavity this moment is second kind of local loading state;

Under second kind of local loading state; The local loading width is said this muscle cavity lateral two times to distance between the adjacent muscle die cavity of this side center; Local loading width l does not change in the stage in local loading, and occurring between the same line journey of sotck thinkness H in second kind of local loading state region is linear relationship; Said muscle cavity lateral is the sidewall that second kind of local loading state one side appears in this muscle die cavity; Adopt formula (1) calculate second kind of local loading state material shunting layer place down arrive muscle die cavity center apart from x _kH in the formula (1) is for second kind of local loading state region sotck thinkness occurring;

Occurring second kind of local loading state region sotck thinkness H in the forming process is confirmed by formula (2) with the relation that loads patrix stroke s: the H in the formula (2) ₀For second kind of local loading state region initial blank thickness occurring;

Flow into the material volume V of muscle die cavity _InConfirm by formula (3);

The third local loading state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib; The surface of said not uniform thickness blank is stepped, and the thickness difference of this ladder is Δ H; Described the third local loading state is between each rib shaping die cavity of bed die; Perhaps between the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie, perhaps between each rib shaping die cavity of bed die and the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie between; And should contact fully with counterdie by the zone blank, the stress state that this moment should the zone is the third local loading state;

Under the third local loading state; The local loading width is and blank occurs in the third local loading state region with all simultaneously two times of the width of contact portion of upper die and lower die; This local loading width l is dynamic change with loading procedure in local loading in the stage, and occurring between H and the same line journey of Δ H in the third local loading state region is nonlinear correlation; Material shunting layer place under the third local loading state to muscle die cavity center apart from x _kConfirm by formula (5):

$\left\{\begin{array}{cc}{x}_k=\frac{b}{2}& {\mathrm{\σ}}_x{|}_{x=b/2}\≤q\\ x_k=\frac{1}{4}(l+b)-\frac{\mathrm{\ΔH}}{2m}(1+\frac{H+\mathrm{\ΔH}}{2b})& {\mathrm{\σ}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(5\right)$

Wherein:

${\mathrm{\σ}}_x{|}_{x=b/2}=\frac{\mathrm{mK}}{\mathrm{\ΔH}}(l-b)$

$q=2K(1+\frac{H+\mathrm{\ΔH}}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; Δ H is for becoming the thickness difference of caliper zones; H is for becoming in the caliper zones not with the sotck thinkness that loads upper mould contact; M is the normal shearing friction factor; σ _xFor material does not flow to the stress of blank X-direction in the muscle die cavity web district, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral; The local coordinate system that is adopted in the formula (5) by blank in the simplifying interface the local coordinate system of inflow muscle die cavity;

In the forming process, the dynamic change of local loading width l is confirmed by formula (6):

l＝l ₀+b ₁s+b ₂s ²(6)

L in the formula ₀Be initial local loading width; S is for loading the patrix stroke; b ₁Be coefficient once; b ₂Be the quadratic term coefficient; b ₁And b ₂Confirm by formula (7) and formula (8) respectively:

ln(b ₁)＝1.16941+0.03880A-0.13668B-0.33010C-0.47077D-0.04376R+0.17274lnA+0.73480lnB-0.39029lnC+0.64892lnR (7)

ln(b ₂)＝-1.01970-0.03751A+0.74384B-0.04876C-0.22359D+1.19454R+0.94165lnA-3.74272lnB-0.45123lnC-1.50094lnR (8)

A is l in the formula ₀The ratio of/b, B are L/l ₀Ratio, C is H ₀The ratio of/b, D are Δ H ₀/ H ₀Ratio; L is muscle die cavity center two times to distance between the restrained end of thickness H biscuit area; R is defined as the ratio of width increment Delta l and thickness difference Δ H for becoming the transition condition of caliper zones, is Δ l/ Δ H;

The thickness difference Δ H that becomes caliper zones in the forming process is confirmed by formula (9):

ΔH＝C ₁-s-H (9)

In the formula: C1 is Δ H ₀Add H ₀Sum; Δ H ₀For original depth poor; H ₀For becoming in the caliper zones not with the initial blank thickness that loads upper mould contact;

Order

K ₁＝L-l ₀，

K ₂＝-b ₁C ₁-b+l ₀，

K ₃＝-2(b ₂C ₁-b ₁)，

${\mathrm{<figure-callout\; id="4"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_4=b_1-\frac{1}{m}-\frac{{\mathrm{<figure-callout\; id="1"\; label="C"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">C</figure-callout>}}_1}{2\mathrm{mb}},$

${\mathrm{<figure-callout\; id="5"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_5={2\mathrm{<figure-callout\; id="2"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_2+\frac{1}{2\mathrm{mb}},$

$K_6=-C_1{\mathrm{<figure-callout\; id="4"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_4+\frac{1}{2}(l_0-b),$

$K_7=\frac{{\mathrm{<figure-callout\; id="1"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_1}{2}+K_4-C_1{\mathrm{<figure-callout\; id="5"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_5,$

${\mathrm{<figure-callout\; id="8"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_8={\mathrm{<figure-callout\; id="5"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_5+\frac{{\mathrm{<figure-callout\; id="2"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_2}{2},$

Said K ₁～K ₈Be the simplification item in (10) and the formula (11);

Flow into the material volume V of muscle die cavity _InConfirm by formula (10) or formula (11) differential equation group:

Work as σ _x| _X=b/2Have during≤q: $\left\{\begin{array}{c}(K_1-b_{1}s-b_2{s}^2)\frac{\mathrm{DH}}{\mathrm{Ds}}-({\mathrm{<figure-callout\; id="1"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_1+{2b}_{2}s)H={\mathrm{<figure-callout\; id="2"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_2+K_{3}s+{3b}_2{\mathrm{<figure-callout\; id="2"\; label="s"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">s</figure-callout>}}^2\\ \frac{{\mathrm{DV}}_{\mathrm{In}}}{\mathrm{Ds}}=\frac{b}{2}\end{array}\right.---\left(10\right)$

Work as σ _x| _X=b/2Have during＞q: $\left\{\begin{array}{c}(K_1-b_{1}s-b_2{s}^2)\frac{\mathrm{DH}}{\mathrm{Ds}}-({\mathrm{<figure-callout\; id="4"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_4+K_{5}s)H=K_6+K_{7}s+K_8{\mathrm{<figure-callout\; id="2"\; label="s"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">s</figure-callout>}}^2\\ \frac{{\mathrm{DV}}_{\mathrm{In}}}{\mathrm{Ds}}=\frac{1}{4}(l_0+b+b_{1}s+b_2{s}^2)-\frac{C_1-s-H}{2m}(1+\frac{C_1-s}{2b})\end{array}\right.---\left(11\right)$

Can find the solution formula (10), formula (11) with numerical method according to initial condition;

Whole stress state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib; Described whole stress state is between each rib shaping die cavity of bed die; Perhaps between the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie, perhaps between each rib shaping die cavity of bed die and the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie between; And should the zone blank contact fully with loading upper die and lower die, the stress state that this moment should the zone is whole stress state;

When the rib shaping die cavity at member one end proximity head place should be whole stress state between end face madial wall of end to said counterdie, then material shunting layer place arrive this rib shaping die cavity center apart from x _kFor said counterdie is somebody's turn to do the distance of the end face madial wall of end to this rib shaping die cavity center;

When being whole stress state between i muscle die cavity and i+1 the muscle die cavity, then material shunting layer place to i muscle die cavity center apart from x _kConfirm by formula (12):

$x_k=\frac{a_{i,i+1}}{2}+\frac{b_i-b_{i+1}}{4}+\frac{{\mathrm{<figure-callout\; id="2"\; label="H"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">H</figure-callout>}}^2}{4m}(\frac{1}{b_{i+1}}-\frac{1}{b_i})---\left(12\right)$

In the formula: a _{I, i+1}It is the distance between i muscle die cavity center and i+1 the muscle die cavity center; b _iThe muscle that is i muscle is wide; b _I+1The muscle that is i+1 muscle is wide; H is for whole stress state zone sotck thinkness occurring; M is the normal shearing friction factor;

Occurring whole stress state zone sotck thinkness H in the forming process is confirmed by formula (13) with the relation that loads patrix stroke s:

H＝H ₀-s (13)

In the formula: H ₀For whole stress state zone initial blank thickness occurring; S is for loading the patrix stroke;

Flow into the material volume V of muscle die cavity _InConfirm by formula (14):

$V_{\mathrm{in}}={\&Integral;}_{s_1}^{s_2}{x}_k\left(s\right)\mathrm{ds}---\left(14\right)$

B. the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle;

First loads the material volume that flows into each muscle die cavity of simplifying interface in the step calculates:

Confirm that first loads the range of patrix, get and calculate step delta s that the span of said Δ s is 0.01～0.1;

In step delta s,, confirm the stress state of i muscle die cavity of simplifying interface both sides, i=1～n according to step a; Calculate the material volume of i the muscle die cavity that flows into simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; I muscle die cavity both sides blank do not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; So far accomplish the calculating of a step delta s; The material volume of each muscle die cavity that record obtains upgrades the blank geometric parameter and contacts situation;

According to step a, repeat said process, continue to confirm the stress state of each muscle die cavity both sides and calculate the material volume that flows into each muscle die cavity; Said continuation is confirmed the stress state of each muscle die cavity both sides and is calculated in the material volume process that flows into each muscle die cavity, and accumulation calculating step delta s until the range of accomplishing the first loading patrix, obtains flowing into the material volume of each muscle die cavity;

After accomplishing the calculating in the first loading step, on the blank shape basis of subregion shaping rib, carry out second and load the material volume calculating that flows into each muscle die cavity of simplifying interface in the step:

Confirm that second loads the range of patrix, get and calculate step delta s that the span of said Δ s is 0.01～0.1;

In step delta s,, confirm the stress state of i muscle die cavity of simplifying interface both sides, i=1～n according to step a; Calculate the material volume of i the muscle die cavity that flows into simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; I muscle die cavity both sides blank do not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; So far accomplish the calculating of a step delta s; The material volume of each muscle die cavity that record obtains upgrades the blank geometric parameter and contacts situation;

According to step a, repeat said process, continue to confirm the stress state of each muscle die cavity both sides and calculate the material volume that flows into each muscle die cavity; The stress state and the calculating that continue definite each muscle die cavity both sides flow in the material volume process of each muscle die cavity, and accumulation calculating step delta s until the range of accomplishing the second loading patrix, obtains flowing into the material volume of each muscle die cavity;

Accomplish two calculating that load the step, the high h of shaping muscle of each muscle is confirmed by formula (15) respectively in the simplifying interface:

$h=\frac{V_{\mathrm{in}}^{\mathrm{tot}}}{b}---\left(15\right)$

Flow into the material volume of muscle die cavity in the formula in

whole forming process;

C. revise not uniform thickness blank based on analysis result, the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle; Revise not uniform thickness blank according to analysis result, and carry out the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle, when the shaping muscle height that calculates with the difference in height e between the designing requirement muscle height _hMaximum max (e _h) during less than 10-15%, stop to revise blank; Obtain the required not uniform thickness blank shape of simplifying interface;

Step 4 is confirmed basically not uniform thickness blank shape;

A. according to the not uniform thickness blank shape on the simplifying interface of step 3 acquisition, confirm not uniform thickness blank of three-dimensional, simultaneously according to the following caliper zones setting principle that becomes:

Become caliper zones transition condition R＞1;

Blank becomes caliper zones and should avoid being arranged near the branch mould position and near the muscle die cavity;

If near muscle die cavity or mould subregion, the change caliper zones is set, need to adopt bigger transition condition, i.e. R＞2;

Obtain the not uniform thickness blank of member thickness direction center line one side;

B. member upper surface and lower surface are distributed with rib symmetrically, with the not uniform thickness blank mirror image that a obtains, make blank upper surface and the lower surface change caliper zones that distributes symmetrically, obtain the integrated member local loading and shaping with three-dimensional uniform thickness blank not basically;

Step 5 is confirmed finally not uniform thickness blank according to the member shape; Confirm not uniform thickness blank through the Computer Numerical Simulation analysis; The forming process of uniform thickness blank not basically in the numerical simulation analysis step 4; First loads the step to the first loading patrix loading, and the second loading step loaded the patrix loading to second; Two load the step back if member shape unmet filling requirement is then revised blank shape according to the three-dimensional numerical value analog result, until the not uniform thickness blank that is met the filling requirement.

The present invention has confirmed to flow into the computing formula of muscle die cavity material volume according to various stress states in the forming process, realizes the rapid analysis of simplifying interface, has shortened the time of definite blank shape; Revise blank shape according to numerical simulation result, confirm to satisfy the not uniform thickness blank of filling requirement, reduced cost; The not uniform thickness stock volume of confirming is distributed rationally, eliminates the defectives such as being not fully filled, folding that exists in the forming process, reduces allowance, reduced shaping load, and blank shape simply is easy to base.

Description of drawings

Fig. 1 is a flow chart of the present invention.

Fig. 2 is different stress state sketch mapes, and wherein, Fig. 2 a is first kind of local loading view; Fig. 2 b is second kind of local loading view; Fig. 2 c is the third local loading view; Fig. 2 d is whole stress state sketch map.

Fig. 3 is that definition becomes caliper zones transition condition sketch map.

Fig. 4 is the structural representation of bulkhead member, and wherein, Fig. 4 a is the structural representation of bulkhead member, and Fig. 4 b is the split sketch map of bulkhead member.

Fig. 5 is that the mould district location reaches the position view of confirming the interface among the embodiment.

Fig. 6 is the uniform thickness blank shape not basically among the embodiment.

Fig. 7 is the numerical simulator among the embodiment.

Fig. 8 is the finally uniform thickness blank shape not among the embodiment.Among the figure,

1. whole counterdie 2. loads patrix 3. and does not load patrix 4. blanks 5. mould district locations

6. frame component 7. gusset shape members 8. subregion muscle 9. interface locations 10. first loading zones

11. second loading zone, 12. whole counterdies 13. first load patrix 14. second and load patrix

15. uniform thickness blank not

The specific embodiment

Present embodiment is that a kind of definite three-dimensional frame component local loading and shaping is used the not method of uniform thickness blank, and the member of present embodiment is a frame component 6, and shown in Fig. 4 b, upper surface and lower surface have the rib of symmetrical distribution; Patrix is divided into two, and subregion muscle 8 centers are the mould district location; The material of member is the TA15 titanium alloy.Forming process in the present embodiment has two and loads the step.

In the present embodiment, three-dimensional frame component local loading and shaping adopts ausforming technology, and forming temperature is 970 ℃, and the patrix loading velocity is 0.2mm/s, and getting friction factor m is 0.3.

The profile of member is divided into two sections in the present embodiment: one section end that is positioned at member, and a side surface of this section is an arcwall face, the opposite side surface is the plane, is approximate planar section; The center line of the member width of this section is parallel with the side surface on plane; Described planar side surface is perpendicular to directions X.Another section is continuous segmental arc, and smooth transition between two sections of member profile; The center line of this section is positioned at the center of member width.Described two sections smooth connections of center line.

Second rib of contiguous this segmental arc end face is as subregion muscle 8 in the selected segmental arc.The center of subregion muscle 8 is the district location of mould, and has formed first loading zone 10 and second loading zone 11 by said mould district location.

Confirm that the detailed process of uniform thickness blank shape not may further comprise the steps:

Step 1 is confirmed the interface of member.The position at interface 9 is as shown in Figure 5.Interface 9 by arc-shaped interface with form and run through two loading zones with the vertical straight line interface two parts of directions X.Described interface 9 is parallel to the center line of member width.Wherein, arc-shaped interface is positioned on the cross section of member segmental arc, and near the internal circular surfaces of arc component, is positioned at 1/3 place of segmental arc cross section.

Step 2 is simplified the interface of confirming;

The upper surface of member and lower surface are distributed with rib symmetrically, and determined interface 9 upper surfaces and lower surface all are distributed with rib symmetrically in the step 1.During simplifying interface, being simplifying interface with symmetrical center line one side of member thickness direction, in the present embodiment, is simplifying interface with lower surface one side of member thickness direction center line.

It is simplifying interface that the back is simplified at interface 9.Have 5 ribs at simplifying interface, be connected the 5th rib that an end is remembered the 1st rib～simplifying interface of making simplifying interface successively with planar section to this segmental arc from an end of segmental arc.Wherein, the 1st rib is the sidewall of segmental arc termination, and the 3rd rib is a subregion muscle 8; And the center line of said the 1st rib～the 4th rib width is crossed the center of circle of said segmental arc, and the 5th rib is vertical with the Y direction.5 ribs of shaping simplifying interface need two to load the step, i.e. local loading and shaping, and the mould district location is the center of subregion muscle 8 in the loading.

Step 3 confirms that the simplifying interface place needs not uniform thickness blank shape.Realize confirming that through simplifying interface being carried out rapid analysis the simplifying interface place needs not uniform thickness blank shape.When simplifying interface is done rapid analysis, get one not the uniform thickness blank and confirm the blank shape of simplifying interface according to initial blank as initial blank.Simplifying interface is done in the rapid analysis, three kinds of local loading states and a kind of whole stress state are arranged.Said three kinds of local loading states are respectively; Because first kind of local loading state that mould part load to form, the second kind of local loading state that forms by the different depth of different webs district mould, and the third local loading state that causes by the step-thickness difference Δ H of the not step-like surface existence of uniform thickness blank.Each simplifying interface is being carried out rapid analysis, each muscle die cavity place of whole counterdie 1 to set up local rectangular coordinate system; The Y coordinate of said local rectangular coordinate system is positioned at the symmetrical centre of muscle die cavity width of living in, and the origin of coordinates of each local rectangular coordinate system is positioned at the intersection point place of this Y coordinate and X coordinate.

Simplifying interface is carried out rapid analysis, confirm the blank shape of simplifying interface.Detailed process:

A. confirm shunting layer position and muscle die cavity filler volume calculation formula according to the stress state in the simplifying interface local loading and shaping.

Need not to wait the geometry characteristic of thick stock, mould according to the simplifying interface place, can three kinds of local loading states of appearance and a kind of whole stress state in the local loading and shaping process.

First kind of local loading state is shown in Fig. 2 a; The blank lower surface cooperates with bed die.Bottom mold surface has the shaping die cavity of rib.Described first kind of local loading state is positioned at loading zone near the complete muscle die cavity of minute first of mould position 5, i.e. the 2nd muscle die cavity in first local loading step and 4th the muscle die cavity of second local loading in the step are to dividing between the mould position 5; Blank in this zone contacts with loading upper die and lower die fully, and stress state that at this moment should the zone is first kind of local loading state.

Under first kind of local loading state; The local loading width is and occurs in first kind of local loading state region near minute complete muscle die cavity of first of mould position 5 center two times to distance between the subregion muscle cavity lateral, and said subregion muscle cavity lateral is the sidewall that first kind of local loading state one side appears in this muscle die cavity.Local loading width l does not change in the stage in local loading, and occurring between the same line journey of sotck thinkness H in first kind of local loading state region is linear relationship.Adopt computing formula (1) calculate first kind of local loading state material shunting layer place down arrive muscle die cavity center apart from x _k:

$\left\{\begin{array}{cc}{x}_k=\frac{\mathrm{<figure-callout\; id="2"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}{2}& {\mathrm{\&sigma;}}_x{|}_{x=b/2}\&le;q\\ x_k=\frac{1}{4}(l+b-\frac{{\mathrm{<figure-callout\; id="2"\; label="H"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">H</figure-callout>}}^2}{\mathrm{mb}})& {\mathrm{\&sigma;}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(1\right)$

Wherein:

${\mathrm{\&sigma;}}_x{|}_{x=b/2}=2K+\frac{\mathrm{mK}}{H}(l-b)$

$q=2K(1+\frac{H}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; H is for first kind of local loading state region sotck thinkness occurring; M is the normal shearing friction factor; σ _xDo not flow to the stress of blank X-direction in the web district of muscle die cavity for material, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral.The local coordinate system that is adopted in the formula (1) by blank in the simplifying interface the local coordinate system of inflow muscle die cavity.

Occurring first kind of local loading state region sotck thinkness H in the forming process is confirmed by formula (2) with the relation that loads patrix stroke s:

H＝H ₀-s (2)

In the formula: H ₀For first kind of local loading state region initial blank thickness occurring; S is for loading the patrix stroke;

Flow into the material volume V of muscle die cavity _InConfirm by formula (3):

$V_{\mathrm{in}}={\&Integral;}_{s_1}^{s_2}{x}_k\left(s\right)\mathrm{ds}---\left(3\right)$

Flow into subregion muscle die cavity, i.e. the 3rd muscle die cavity, material volume V _OutConfirm by formula (4):

$V_{\mathrm{out}}={\&Integral;}_{s_1}^{s_2}[\frac{l}{2}-x_k\left(s\right)]\mathrm{ds}---\left(4\right)$

Second kind of local loading state is shown in Fig. 2 b; The blank lower surface cooperates with bed die.Bottom mold surface has the shaping die cavity of rib.The 2nd muscle both sides web thickness changes; In first local loading goes on foot; Blank between the 2nd muscle die cavity and the 3rd muscle die cavity contacts with loading upper die and lower die fully; And the blank between the 2nd muscle die cavity and the 1st muscle does not contact with loading upper die and lower die fully, and the stress state between this moment the 2nd muscle die cavity and the 3rd the muscle die cavity is second kind of local loading state.

Under second kind of local loading state; The local loading width is 2 the muscle die cavities in the 3rd muscle die cavity center to the two times near distance between the sidewall of the 3rd muscle die cavity; Local loading width l does not change in the stage in local loading, and occurring between the same line journey of sotck thinkness H in second kind of local loading state region is linear relationship.Adopt computing formula (1) calculate second kind of local loading state material shunting layer place down arrive muscle die cavity center apart from x _k:

$\left\{\begin{array}{cc}{x}_k=\frac{\mathrm{<figure-callout\; id="2"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}{2}& {\mathrm{\&sigma;}}_x{|}_{x=b/2}\&le;q\\ x_k=\frac{1}{4}(l+b-\frac{{\mathrm{<figure-callout\; id="2"\; label="H"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">H</figure-callout>}}^2}{\mathrm{mb}})& {\mathrm{\&sigma;}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(1\right)$

Wherein:

${\mathrm{\&sigma;}}_x{|}_{x=b/2}=2K+\frac{\mathrm{mK}}{H}(l-b)$

$q=2K(1+\frac{H}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; H is for second kind of local loading state region sotck thinkness occurring; M is the normal shearing friction factor; σ _xDo not flow to the stress of blank X-direction in the web district of muscle die cavity for material, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral.The local coordinate system that is adopted in the formula (1) by blank in the simplifying interface the local coordinate system of inflow muscle die cavity.

Occurring second kind of local loading state region sotck thinkness H in the forming process is confirmed by formula (2) with the relation that loads patrix stroke s:

H＝H ₀-s (2)

In the formula: H ₀For second kind of local loading state region initial blank thickness occurring; S is for loading the patrix stroke;

Flow into the material volume V of muscle die cavity _InConfirm by formula (3):

$V_{\mathrm{in}}={\&Integral;}_{s_1}^{s_2}{x}_k\left(s\right)\mathrm{ds}---\left(3\right)$

The third local loading state is shown in Fig. 2 c; The blank lower surface cooperates with bed die.Bottom mold surface has the shaping die cavity of rib.The surface of said not uniform thickness blank is stepped, and the thickness difference of this ladder is Δ H.Described the third local loading state is between each rib shaping die cavity of bed die; Perhaps between the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie, perhaps between each rib shaping die cavity of bed die and the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie between; And should contact fully with counterdie by the zone blank, the stress state that this moment should the zone is the third local loading state.

Under the third local loading state; The local loading width is and blank occurs in the third local loading state region with all simultaneously two times of the width of contact portion of upper die and lower die; This local loading width l is dynamic change with loading procedure in local loading in the stage, and occurring between H and the same line journey of Δ H in the third local loading state region is nonlinear correlation.Material shunting layer place under the third local loading state to muscle die cavity center apart from x _kConfirm by formula (5):

$\left\{\begin{array}{cc}{x}_k=\frac{\mathrm{<figure-callout\; id="2"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}{2}& {\mathrm{\&sigma;}}_x{|}_{x=b/2}\&le;q\\ x_k=\frac{1}{4}(l+b)-\frac{\mathrm{\&Delta;H}}{2m}(1+\frac{H+\mathrm{\&Delta;H}}{2b})& {\mathrm{\&sigma;}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(5\right)$

Wherein:

${\mathrm{\&sigma;}}_x{|}_{x=b/2}=\frac{\mathrm{mK}}{\mathrm{\&Delta;H}}(l-b)$

$q=2K(1+\frac{H+\mathrm{\&Delta;H}}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; Δ H is for becoming the thickness difference of caliper zones; H is for becoming in the caliper zones not with the sotck thinkness that loads upper mould contact; M is the normal shearing friction factor; σ _xDo not flow to the stress of blank X-direction in the web district of muscle die cavity for material, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral.The local coordinate system that is adopted in the formula (5) by blank in the simplifying interface the local coordinate system of inflow muscle die cavity.

In the forming process, the dynamic change of local loading width l is confirmed by formula (6):

l＝l ₀+b ₁s+b ₂s ²(6)

L in the formula ₀Be initial local loading width; S is for loading the patrix stroke; b ₁Be coefficient once; b ₂Be the quadratic term coefficient; b ₁And b ₂Confirm by formula (7) and formula (8) respectively:

ln(b ₁)＝1.16941+0.03880A-0.13668B-0.33010C-0.47077D-0.04376R+0.17274lnA+0.73480lnB-0.39029lnC+0.64892lnR (7)

ln(b ₂)＝-1.01970-0.03751A+0.74384B-0.04876C-0.22359D+1.19454R+0.94165lnA-3.74272lnB-0.45123lnC-1.50094lnR (8)

In the formula: A is l ₀The ratio of/b, B are L/l ₀Ratio, C is H ₀The ratio of/b, D are Δ H ₀/ H ₀Ratio; L is muscle die cavity center two times to distance between the restrained end of thickness H biscuit area; R is defined as the ratio of width increment Delta l and thickness difference Δ H for becoming the transition condition of caliper zones, is Δ l/ Δ H, and is as shown in Figure 3;

The thickness difference Δ H that becomes caliper zones in the forming process is confirmed by formula (9):

ΔH＝C ₁-s-H (9)

In the formula: C ₁Be Δ H ₀Add H ₀Sum; Δ H ₀For original depth poor; H ₀For becoming in the caliper zones not with the initial blank thickness that loads upper mould contact;

Order

K ₁＝L-l ₀，

K ₂＝-b ₁C ₁-b+l ₀，

K ₃＝-2(b ₂C ₁-b ₁)，

${\mathrm{<figure-callout\; id="4"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_4=b_1-\frac{1}{m}-\frac{{\mathrm{<figure-callout\; id="1"\; label="C"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">C</figure-callout>}}_1}{2\mathrm{mb}},$

${\mathrm{<figure-callout\; id="5"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_5={2\mathrm{<figure-callout\; id="2"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_2+\frac{1}{2\mathrm{mb}},$

$K_6=-C_1{\mathrm{<figure-callout\; id="4"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_4+\frac{1}{2}(l_0-b),$

$K_7=\frac{{\mathrm{<figure-callout\; id="1"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_1}{2}+K_4-C_1{\mathrm{<figure-callout\; id="5"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_5,$

${\mathrm{<figure-callout\; id="8"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_8={\mathrm{<figure-callout\; id="5"\; label="K"\; filenames="HDA0000138840120000031.png"\; state="\{\{state\}\}">K</figure-callout>}}_5+\frac{{\mathrm{<figure-callout\; id="2"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_2}{2},$

Said K ₁～K ₈Be the simplification item in (10) and the formula (11).

Flow into the material volume V of muscle die cavity _InConfirm by formula (10) or formula (11) differential equation group:

Work as σ _x| _X=b/2Have during≤q: $\left\{\begin{array}{c}(K_1-b_{1}s-b_2{s}^2)\frac{\mathrm{DH}}{\mathrm{Ds}}-({\mathrm{<figure-callout\; id="1"\; label="b"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">b</figure-callout>}}_1+{2b}_{2}s)H={\mathrm{<figure-callout\; id="2"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_2+K_{3}s+{3b}_2{\mathrm{<figure-callout\; id="2"\; label="s"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">s</figure-callout>}}^2\\ \frac{{\mathrm{DV}}_{\mathrm{In}}}{\mathrm{Ds}}=\frac{b}{2}\end{array}\right.---\left(10\right)$

Work as σ _x| _X=b/2Have during＞q: $\left\{\begin{array}{c}(K_1-b_{1}s-b_2{s}^2)\frac{\mathrm{DH}}{\mathrm{Ds}}-({\mathrm{<figure-callout\; id="4"\; label="K"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">K</figure-callout>}}_4+K_{5}s)H=K_6+K_{7}s+K_8{\mathrm{<figure-callout\; id="2"\; label="s"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">s</figure-callout>}}^2\\ \frac{{\mathrm{DV}}_{\mathrm{In}}}{\mathrm{Ds}}=\frac{1}{4}(l_0+b+b_{1}s+b_2{s}^2)-\frac{C_1-s-H}{2m}(1+\frac{C_1-s}{2b})\end{array}\right.---\left(11\right)$

Use numerical method according to initial condition, find the solution formula (10), formula (11), adopt Runge-Kutta method to find the solution formula (10), formula (11) in the present embodiment.

Whole stress state is shown in Fig. 2 d; The blank lower surface cooperates with bed die.Bottom mold surface has the shaping die cavity of rib.Described whole stress state is between each rib shaping die cavity of bed die; Perhaps between the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie, perhaps between each rib shaping die cavity of bed die and the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie between; And should the zone blank contact fully with loading upper die and lower die, the stress state that this moment should the zone is whole stress state.

When the rib shaping die cavity at member one end proximity head place should be whole stress state between end face madial wall of end to said counterdie, then material shunting layer place arrive this rib shaping die cavity center apart from x _kFor said counterdie is somebody's turn to do the distance of the end face madial wall of end to this rib shaping die cavity center.

When being whole stress state between i muscle die cavity and i+1 the muscle die cavity, then material shunting layer place to i muscle die cavity center apart from x _kConfirm by formula (12):

$x_k=\frac{a_{i,i+1}}{2}+\frac{b_i-b_{i+1}}{4}+\frac{{\mathrm{<figure-callout\; id="2"\; label="H"\; filenames="HDA0000138840120000013.png,HDA0000138840120000021.png"\; state="\{\{state\}\}">H</figure-callout>}}^2}{4m}(\frac{1}{b_{i+1}}-\frac{1}{b_i})---\left(12\right)$

In the formula: a _{I, i+1}It is the distance between i muscle die cavity center and i+1 the muscle die cavity center; b _iThe muscle that is i muscle is wide; b _I+1The muscle that is i+1 muscle is wide; H is for whole stress state zone sotck thinkness occurring; M is the normal shearing friction factor;

Occurring whole stress state zone sotck thinkness H in the forming process is confirmed by formula (13) with the relation that loads patrix stroke s:

H＝H ₀-s (13)

In the formula: H ₀For whole stress state zone initial blank thickness occurring; S is for loading the patrix stroke;

Flow into the material volume V of muscle die cavity _InConfirm by formula (14):

$V_{\mathrm{in}}={\&Integral;}_{s_1}^{s_2}{x}_k\left(s\right)\mathrm{ds}---\left(14\right)$

B. the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle;

First loads the material volume that flows into each muscle die cavity of simplifying interface in the step calculates:

Confirm that first loads the range of patrix, getting and calculating step-length is Δ s.The span of said Δ s is 0.01～0.1, Δ s=0.05mm in the present embodiment;

In step delta s, according to step a, confirm the stress state of the 1st muscle die cavity both sides of simplifying interface, calculate the material volume of the 1st the muscle die cavity that flows into simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; The 1st muscle die cavity both sides blank do not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; Repeat said process,, confirm the stress state of the 2nd muscle die cavity both sides, the 3rd muscle die cavity both sides, the 4th muscle die cavity both sides and the 5th muscle die cavity both sides respectively according to step a.Calculate the material volume of the 2nd muscle die cavity, the 3rd muscle die cavity, the 4th muscle die cavity and the 5th muscle die cavity that flow into simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; The 2nd muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; The 3rd muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume also is zero; The 4th muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume also is zero; The 5th muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume also is zero.So far accomplish the calculating of a step delta s.The material volume of each muscle die cavity that record obtains upgrades the blank geometric parameter and contacts situation.

Based on step a, repeat said process, continue to confirm the stress state of each muscle die cavity both sides and calculate the material volume that flows into each muscle die cavity.In the computational process, accumulation calculating step delta s until the range of accomplishing the first loading patrix, obtains flowing into the material volume of each muscle die cavity.

After accomplishing the calculating in the first loading step, on the blank shape basis of subregion shaping rib, carry out second and load the material volume calculating that flows into each muscle die cavity of simplifying interface in the step:

Confirm that second loads the range of patrix, getting and calculating step-length is Δ s.The span of said Δ s is 0.01～0.1, Δ s=0.05mm in the present embodiment;

In step delta s, according to step a, confirm the stress state of the 1st muscle die cavity both sides of simplifying interface, calculate the material volume of the 1st the muscle die cavity that flows into simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; The 1st muscle die cavity both sides blank do not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; Repeat said process,, confirm the stress state of the 2nd muscle die cavity both sides, the 3rd muscle die cavity both sides, the 4th muscle die cavity both sides and the 5th muscle die cavity both sides respectively according to step a.Calculate the material volume of the 2nd muscle die cavity, the 3rd muscle die cavity, the 4th muscle die cavity and the 5th muscle die cavity that flow into second simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; The 2nd muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; The 3rd muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume also is zero; The 4th muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume also is zero; The 5th muscle die cavity both sides blank does not contact with bed die with mold, and flowing into muscle die cavity material volume also is zero.So far accomplish the calculating of a step delta s.The material volume of each muscle die cavity that record obtains upgrades the blank geometric parameter and contacts situation.

Based on step a, repeat said process, continue to confirm the stress state of each muscle die cavity both sides and calculate the material volume that flows into each muscle die cavity.In the computational process, accumulation calculating step delta s until the range of accomplishing the second loading patrix, obtains flowing into the material volume of each muscle die cavity.

Accomplish two calculating that load the step, the high h of shaping muscle of each muscle is confirmed by formula (15) respectively in the simplifying interface:

$h=\frac{V_{\mathrm{in}}^{\mathrm{tot}}}{b}---\left(15\right)$

Flow into the material volume of muscle die cavity in the formula in

whole forming process.

C. revise not uniform thickness blank based on analysis result, the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle.Revise not uniform thickness blank according to analysis result, and carry out the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle, when the shaping muscle height that calculates with the difference in height e between the designing requirement muscle height _hMaximum max (e _h) during less than 10-15%, stop to revise blank; Obtain the required not uniform thickness blank shape of simplifying interface.

Step 4 is confirmed basically not uniform thickness blank shape;

A. according to the not uniform thickness blank shape on the simplifying interface of step 3 acquisition, confirm not uniform thickness blank of three-dimensional, simultaneously according to the following caliper zones setting principle that becomes:

Become caliper zones transition condition R＞1;

Blank becomes caliper zones and should avoid being arranged near the branch mould position and near the muscle die cavity;

If near muscle die cavity or mould subregion, the change caliper zones is set, need to adopt bigger transition condition, i.e. R＞2;

Obtain the not uniform thickness blank of member thickness direction center line one side.

B. member upper surface and lower surface are distributed with rib symmetrically, with the not uniform thickness blank mirror image that a obtains, make blank upper surface and the lower surface change caliper zones that distributes symmetrically, and be as shown in Figure 6, obtains the integrated member local loading and shaping with three-dimensional uniform thickness blank not basically.

Step 5 is confirmed finally not uniform thickness blank according to the member shape.Confirm not uniform thickness blank through the Computer Numerical Simulation analysis.The forming process of uniform thickness blank not basically in the numerical simulation analysis step 4.Fig. 7 is a component partial loading and shaping numerical Simulation model, and this numerical simulator comprises that whole counterdie 12, first loads patrix 13, second and loads patrix 14 and uniform thickness blank 15 not; First loads the step to 13 loadings of the first loading patrix, and the second loading step loaded patrix 14 loadings to second.Two load step rear arc section end face underfill, revise blank shape based on the three-dimensional numerical value analog result, until satisfying the filling requirement, obtain final blank., as shown in Figure 8 in the present embodiment through once revising the not uniform thickness blank that obtains to satisfy the filling requirement.

Claims (1)

1. a definite three-dimensional frame component local loading and shaping is used the not method of uniform thickness blank, it is characterized in that, may further comprise the steps:

Step 1 is confirmed the interface of member; The interface by arc-shaped interface with form and run through two loading zones with the vertical straight line interface two parts of directions X; Described interface is parallel to the center line of member width

Step 2 is simplified the interface of confirming; Determined interface upper surface and lower surface all are distributed with a plurality of ribs symmetrically; Symmetrical center line one side with the member thickness direction is a simplifying interface, and each rib in this simplifying interface is designated as i muscle, i=1～n respectively; The rib of shaping simplifying interface adopts local loading and shaping, and the mould district location is the center of subregion muscle in the loading; Confirm that a rib in the 2nd muscle～n-1 muscle is the subregion muscle;

Step 3 confirms that the simplifying interface place needs not uniform thickness blank shape; Realize confirming that through simplifying interface being carried out rapid analysis the simplifying interface place needs not uniform thickness blank shape; When simplifying interface is done rapid analysis, get one not the uniform thickness blank and confirm the blank shape of simplifying interface according to initial blank as initial blank; Simplifying interface is done in the rapid analysis, three kinds of local loading states and a kind of whole stress state are arranged; Said three kinds of local loading states are respectively; Because first kind of local loading state that mould part load to form, the second kind of local loading state that forms by the different depth of different webs district mould, and the third local loading state that causes by the step-thickness difference Δ H of the not step-like surface existence of uniform thickness blank; Each simplifying interface is being carried out rapid analysis, each muscle die cavity place of whole counterdie to set up local rectangular coordinate system; The Y coordinate of said local rectangular coordinate system is positioned at the symmetrical centre of muscle die cavity width of living in, and the origin of coordinates of each local rectangular coordinate system is positioned at the intersection point place of this Y coordinate and X coordinate;

Simplifying interface is carried out rapid analysis, confirm the blank shape of simplifying interface; Detailed process:

A. confirm shunting layer position and muscle die cavity filler volume calculation formula according to the stress state in the simplifying interface local loading and shaping;

Need not to wait the geometry characteristic of thick stock, mould according to the simplifying interface place, can three kinds of local loading states of appearance and a kind of whole stress state in the local loading and shaping process;

First kind of local loading state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib;

Described first kind of local loading state arrives between the branch mould position near the complete muscle die cavity of minute first of mould position in loading zone; Blank in this zone contacts with loading upper die and lower die fully, and stress state that at this moment should the zone is first kind of local loading state;

Under first kind of local loading state; The local loading width is and occurs in first kind of local loading state region near minute complete muscle die cavity of first of mould position center two times to distance between the subregion muscle cavity lateral, and said subregion muscle cavity lateral is the sidewall that first kind of local loading state one side appears in this muscle die cavity; Local loading width l does not change in the stage in local loading, and occurring between the same line journey of sotck thinkness H in first kind of local loading state region is linear relationship; Adopt computing formula (1) calculate first kind of local loading state material shunting layer place down arrive muscle die cavity center apart from x _k:

$\left\{\begin{array}{cc}{x}_k=\frac{b}{2}& {\mathrm{\&sigma;}}_x{|}_{x=b/2}\&le;q\\ x_k=\frac{1}{4}(l+b-\frac{H^2}{\mathrm{mb}})& {\mathrm{\&sigma;}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(1\right)$

Wherein:

${\mathrm{\&sigma;}}_x{|}_{x=b/2}=2K+\frac{\mathrm{mK}}{H}(l-b)$

$q=2K(1+\frac{H}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; H is for first kind of local loading state region sotck thinkness occurring; M is the normal shearing friction factor; σ _xDo not flow to the stress of blank X-direction in the web district of muscle die cavity for material, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral; The local coordinate system that is adopted in the formula (1) by blank in the simplifying interface the local coordinate system of inflow muscle die cavity;

Occurring first kind of local loading state region sotck thinkness H in the forming process is confirmed by formula (2) with the relation that loads patrix stroke s:

H＝H ₀-s (2)

In the formula: H ₀For first kind of local loading state region initial blank thickness occurring; S is for loading the patrix stroke;

Flow into the material volume V of muscle die cavity _InConfirm by formula (3):

$V_{\mathrm{in}}={\&Integral;}_{s_1}^{s_2}{x}_k\left(s\right)\mathrm{ds}---\left(3\right)$

Flow into the material volume V of subregion muscle die cavity _OutConfirm by formula (4):

$V_{\mathrm{out}}={\&Integral;}_{s_1}^{s_2}[\frac{l}{2}-x_k\left(s\right)]\mathrm{ds}---\left(4\right)$

Second kind of local loading state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib; The both sides web thickness of muscle changes; In loading and shaping; Blank between the adjacent muscle die cavity with a side of this muscle die cavity contacts with loading upper die and lower die fully; And the blank between the adjacent muscle die cavity with opposite side of said this muscle die cavity does not contact with loading upper die and lower die fully, and the stress state between the adjacent muscle die cavity with a said side of said this muscle die cavity this moment is second kind of local loading state;

Under second kind of local loading state; The local loading width is said this muscle cavity lateral two times to distance between the adjacent muscle die cavity of this side center; Local loading width l does not change in the stage in local loading, and occurring between the same line journey of sotck thinkness H in second kind of local loading state region is linear relationship; Said muscle cavity lateral is the sidewall that second kind of local loading state one side appears in this muscle die cavity; Adopt formula (1) calculate second kind of local loading state material shunting layer place down arrive muscle die cavity center apart from x _kH in the formula (1) is for second kind of local loading state region sotck thinkness occurring;

Occurring second kind of local loading state region sotck thinkness H in the forming process is confirmed by formula (2) with the relation that loads patrix stroke s: the H in the formula (2) ₀For second kind of local loading state region initial blank thickness occurring;

Flow into the material volume V of muscle die cavity _InConfirm by formula (3);

The third local loading state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib; The surface of said not uniform thickness blank is stepped, and the thickness difference of this ladder is Δ H; Described the third local loading state is between each rib shaping die cavity of bed die; Perhaps between the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie, perhaps between each rib shaping die cavity of bed die and the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie between; And should contact fully with counterdie by the zone blank, the stress state that this moment should the zone is the third local loading state;

Under the third local loading state; The local loading width is and blank occurs in the third local loading state region with all simultaneously two times of the width of contact portion of upper die and lower die; This local loading width l is dynamic change with loading procedure in local loading in the stage, and occurring between H and the same line journey of Δ H in the third local loading state region is nonlinear correlation; Material shunting layer place under the third local loading state to muscle die cavity center apart from x _kConfirm by formula (5):

$\left\{\begin{array}{cc}{x}_k=\frac{b}{2}& {\mathrm{\&sigma;}}_x{|}_{x=b/2}\&le;q\\ x_k=\frac{1}{4}(l+b)-\frac{\mathrm{\&Delta;H}}{2m}(1+\frac{H+\mathrm{\&Delta;H}}{2b})& {\mathrm{\&sigma;}}_x{|}_{x=b/2}>q\end{array}\right.\text{---}\left(5\right)$

Wherein:

${\mathrm{\&sigma;}}_x{|}_{x=b/2}=\frac{\mathrm{mK}}{\mathrm{\&Delta;H}}(l-b)$

$q=2K(1+\frac{H+\mathrm{\&Delta;H}}{2b})$

In the formula: K is the material shear yield strength; B is that muscle is wide; L is the local loading width; Δ H is for becoming the thickness difference of caliper zones; H is for becoming in the caliper zones not with the sotck thinkness that loads upper mould contact; M is the normal shearing friction factor; σ _xFor material does not flow to the stress of blank X-direction in the muscle die cavity web district, blank contacts with loading upper die and lower die simultaneously in the described web district; Q is the average unit pressure of the X-direction on interior muscle of blank and the web intersection interface, and described muscle and web intersection interface overlap with the muscle cavity lateral; The local coordinate system that is adopted in the formula (5) by blank in the simplifying interface the local coordinate system of inflow muscle die cavity;

In the forming process, the dynamic change of local loading width l is confirmed by formula (6):

l＝l ₀+b ₁s+b ₂s ²(6)

L in the formula ₀Be initial local loading width; S is for loading the patrix stroke; b ₁Be coefficient once; b ₂Be the quadratic term coefficient; b ₁And b ₂Confirm by formula (7) and formula (8) respectively:

ln(b ₁)＝1.16941+0.03880A-0.13668B-0.33010C-0.47077D-0.04376R+0.17274lnA+0.73480lnB-0.39029lnC+0.64892lnR (7)

ln(b ₂)＝-1.01970-0.03751A+0.74384B-0.04876C-0.22359D+1.19454R+0.94165lnA-3.74272lnB-0.45123lnC-1.50094lnR (8)

A is l in the formula ₀The ratio of/b, B are L/l ₀Ratio, C is H ₀The ratio of/b, D are Δ H ₀/ H ₀Ratio;

L is muscle die cavity center two times to distance between the restrained end of thickness H biscuit area; R is defined as the ratio of width increment Delta l and thickness difference Δ H for becoming the transition condition of caliper zones, is Δ l/ Δ H;

The thickness difference Δ H that becomes caliper zones in the forming process is confirmed by formula (9):

ΔH＝C ₁-s-H (9)

In the formula: C1 is Δ H ₀Add H ₀Sum; Δ H ₀For original depth poor; H ₀For becoming in the caliper zones not with the initial blank thickness that loads upper mould contact;

Order

K ₁＝L-l ₀，

K ₂＝-b ₁C ₁-b+l ₀，

K ₃＝-2(b ₂C ₁-b ₁)，

$K_4=b_1-\frac{1}{m}-\frac{C_1}{2\mathrm{mb}},$

$K_5={2b}_2+\frac{1}{2\mathrm{mb}},$

$K_6=-C_1{K}_4+\frac{1}{2}(l_0-b),$

$K_7=\frac{b_1}{2}+K_4-C_1{K}_5,$

$K_8=K_5+\frac{b_2}{2},$

Said K ₁～K ₈Be the simplification item in (10) and the formula (11);

Flow into the material volume V of muscle die cavity _InConfirm by formula (10) or formula (11) differential equation group:

Work as σ _x| _X=b/2Have during≤q: $\left\{\begin{array}{c}(K_1-b_{1}s-b_2{s}^2)\frac{\mathrm{DH}}{\mathrm{Ds}}-(b_1+{2b}_{2}s)H=K_2+K_{3}s+{3b}_2{s}^2\\ \frac{{\mathrm{DV}}_{\mathrm{In}}}{\mathrm{Ds}}=\frac{b}{2}\end{array}\right.---\left(10\right)$

Work as σ _x| _X=b/2Have during＞q: $\left\{\begin{array}{c}(K_1-b_{1}s-b_2{s}^2)\frac{\mathrm{DH}}{\mathrm{Ds}}-(K_4+K_{5}s)H=K_6+K_{7}s+K_8{s}^2\\ \frac{{\mathrm{DV}}_{\mathrm{In}}}{\mathrm{Ds}}=\frac{1}{4}(l_0+b+b_{1}s+b_2{s}^2)-\frac{C_1-s-H}{2m}(1+\frac{C_1-s}{2b})\end{array}\right.---\left(11\right)$

Can find the solution formula (10), formula (11) with numerical method according to initial condition;

Whole stress state; The blank lower surface cooperates with bed die; Bottom mold surface has the shaping die cavity of rib; Described whole stress state is between each rib shaping die cavity of bed die; Perhaps between the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie, perhaps between each rib shaping die cavity of bed die and the rib shaping die cavity at member one end proximity head place should the end face madial wall of end to said counterdie between; And should the zone blank contact fully with loading upper die and lower die, the stress state that this moment should the zone is whole stress state;

When the rib shaping die cavity at member one end proximity head place should be whole stress state between end face madial wall of end to said counterdie, then material shunting layer place arrive this rib shaping die cavity center apart from x _kFor said counterdie is somebody's turn to do the distance of the end face madial wall of end to this rib shaping die cavity center;

When being whole stress state between i muscle die cavity and i+1 the muscle die cavity, then material shunting layer place to i muscle die cavity center apart from x _kConfirm by formula (12):

$x_k=\frac{a_{i,i+1}}{2}+\frac{b_i-b_{i+1}}{4}+\frac{H^2}{4m}(\frac{1}{b_{i+1}}-\frac{1}{b_i})---\left(12\right)$

In the formula: a _{I, i+1}It is the distance between i muscle die cavity center and i+1 the muscle die cavity center; b _iThe muscle that is i muscle is wide; b _I+1The muscle that is i+1 muscle is wide; H is for whole stress state zone sotck thinkness occurring; M is the normal shearing friction factor;

Occurring whole stress state zone sotck thinkness H in the forming process is confirmed by formula (13) with the relation that loads patrix stroke s:

H＝H ₀-s (13)

In the formula: H ₀For whole stress state zone initial blank thickness occurring; S is for loading the patrix stroke;

Flow into the material volume V of muscle die cavity _InConfirm by formula (14):

$V_{\mathrm{in}}={\&Integral;}_{s_1}^{s_2}{x}_k\left(s\right)\mathrm{ds}---\left(14\right)$

B. the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle;

First loads the material volume that flows into each muscle die cavity of simplifying interface in the step calculates:

Confirm that first loads the range of patrix, get and calculate step delta s that the span of said Δ s is 0.01～0.1; In step delta s,, confirm the stress state of i muscle die cavity of simplifying interface both sides, i=1～n according to step a; Calculate the material volume of i the muscle die cavity that flows into simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; I muscle die cavity both sides blank do not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; So far accomplish the calculating of a step delta s; The material volume of each muscle die cavity that record obtains upgrades the blank geometric parameter and contacts situation;

According to step a, repeat said process, continue to confirm the stress state of each muscle die cavity both sides and calculate the material volume that flows into each muscle die cavity; Said continuation is confirmed the stress state of each muscle die cavity both sides and is calculated in the material volume process that flows into each muscle die cavity, and accumulation calculating step delta s until the range of accomplishing the first loading patrix, obtains flowing into the material volume of each muscle die cavity;

After accomplishing the calculating in the first loading step, on the blank shape basis of subregion shaping rib, carry out second and load the material volume calculating that flows into each muscle die cavity of simplifying interface in the step:

Confirm that second loads the range of patrix, get and calculate step delta s that the span of said Δ s is 0.01～0.1; In step delta s,, confirm the stress state of i muscle die cavity of simplifying interface both sides, i=1～n according to step a; Calculate the material volume of i the muscle die cavity that flows into simplifying interface respectively according to geometric parameter, the friction condition of stress state, muscle die cavity and blank; I muscle die cavity both sides blank do not contact with bed die with mold, and flowing into muscle die cavity material volume is zero; So far accomplish the calculating of a step delta s; The material volume of each muscle die cavity that record obtains upgrades the blank geometric parameter and contacts situation;

According to step a, repeat said process, continue to confirm the stress state of each muscle die cavity both sides and calculate the material volume that flows into each muscle die cavity; The stress state and the calculating that continue definite each muscle die cavity both sides flow in the material volume process of each muscle die cavity, and accumulation calculating step delta s until the range of accomplishing the second loading patrix, obtains flowing into the material volume of each muscle die cavity;

Accomplish two calculating that load the step, the high h of shaping muscle of each muscle is confirmed by formula (15) respectively in the simplifying interface:

$h=\frac{V_{\mathrm{in}}^{\mathrm{tot}}}{b}---\left(15\right)$

Flow into the material volume of muscle die cavity in the formula in whole forming process;

C. revise not uniform thickness blank based on analysis result, the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle; Revise not uniform thickness blank according to analysis result, and carry out the high analytical Calculation of simplifying interface local loading and shaping process shaping muscle, when the shaping muscle height that calculates with the difference in height e between the designing requirement muscle height _hMaximum max (e _h) during less than 10-15%, stop to revise blank; Obtain the required not uniform thickness blank shape of simplifying interface;

Step 4 is confirmed basically not uniform thickness blank shape;

A. according to the not uniform thickness blank shape on the simplifying interface of step 3 acquisition, confirm not uniform thickness blank of three-dimensional, simultaneously according to the following caliper zones setting principle that becomes:

Become caliper zones transition condition R＞1;

Blank becomes caliper zones and should avoid being arranged near the branch mould position and near the muscle die cavity;

If near muscle die cavity or mould subregion, the change caliper zones is set, need to adopt bigger transition condition, i.e. R＞2;

Obtain the not uniform thickness blank of member thickness direction center line one side;

B. member upper surface and lower surface are distributed with rib symmetrically, with the not uniform thickness blank mirror image that a obtains, make blank upper surface and the lower surface change caliper zones that distributes symmetrically, obtain the integrated member local loading and shaping with three-dimensional uniform thickness blank not basically;

Step 5 is confirmed finally not uniform thickness blank according to the member shape; Confirm not uniform thickness blank through the Computer Numerical Simulation analysis; The forming process of uniform thickness blank not basically in the numerical simulation analysis step 4; First loads the step to the first loading patrix loading, and the second loading step loaded the patrix loading to second; Two load the step back if member shape unmet filling requirement is then revised blank shape according to the three-dimensional numerical value analog result, until the not uniform thickness blank that is met the filling requirement.

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