CN104077439A - Numerical simulation method of novel high-strength steel spoke drawing punching combined process - Google Patents
Numerical simulation method of novel high-strength steel spoke drawing punching combined process Download PDFInfo
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Abstract
The invention discloses a numerical simulation method of a novel high-strength steel spoke drawing punching combined process. By means of establishment of an accurate finite element model, a forming process of a novel high strength steel plate for spoke production can be observed, distribution of wall thickness, stress, strain and damages in the spoke forming process can be obtained, possible forming defects such as excessively thinning and pull cracks of the plate in the spoke forming process can be discovered in time, forming properties of the plate can be evaluated in advance before the novel high strength steel plate is used for spoke actual production, thereby, the process design scheme can be effectively improved, mold parameters can be optimized, spoke product qualities are improved, rejection rate of products is reduced, large manpower and material inputs caused by trial and error can be avoided, the market competitiveness of the high-strength steel products is improved, application and development of novel high-strength steel wheels are facilitated, and the basis is provided for optimization of steel for high-strength wheels.
Description
One, technical field
The invention belongs to wheel spoke and manufacture field, specifically a kind of method for numerical simulation of novel high-strength steel wheel spoke pull and stretch punching compound working procedure.
Two, background technology
Wheel spoke is the main support part that connects automobile rim and wheel hub, is also the critical component of wheel safety, manufactures the traditional material of spoke and mainly contains aluminium alloy and mild carbon steel.Along with auto industry is to the improving constantly of security performance and product lightweight requirements, high-strength steel is widely used in spoke in the advantage aspect security and economy and is shaped compared with light material is low etc. owing to having compared with low yield tensile ratio and cost.
Spoke stamping forming technology is comprised of multiple working procedure, comprises pull and stretch punching, moulding, trimming, rushes wind hole, presses wind hole bur etc.In production, the normal first operation that adopts pull and stretch punching compound working procedure to be shaped as spoke, can reduce operation passage, shortens total curring time, enhances productivity and reduces production costs, and is particularly suitable for producing in enormous quantities.Because in this operation, workpiece deformation amount is large, mold shape is complicated, in spoke forming process, there will be the even defect such as drawing crack of wall thickness reduction, directly have influence on the final forming quality of spoke.Therefore, pull and stretch punching operation is to determine the very important process procedure of spoke quality.
Along with the development of rolling mill practice and the demand of auto industry, the novel high-strength steel plate material that intensity is high, shaping difficulty is large is more and more extensive in the manufacturing application of spoke.Novel high-strength steel plate material when being shaped for spoke stamping, because its intensity is high, shaping narrow range, the difficulty that causes being shaped is large and forming quality is wayward; And it is improper to work as Design of Dies and process parameters design, and spoke there will be local reduction, the even defects such as cracking that even occur of wall unevenness.Therefore predict accurately the defect that novel high-strength steel plate material may occur for spoke forming process and reasonably carry out Design of Dies Optimizing Process Parameters manufacturing the promoting the use of of automobile spoke, to there is very important practical significance for it.For high-strength steel wheel spoke stamping forming technology, existing research method is mainly to rely on trial and error repeatedly, has cycle length, high in cost of production shortcoming, has seriously restricted novel high-strength Steel material and has manufactured promoting the use of of field at passenger car wheel spoke.
Three, summary of the invention
The object of the present invention is to provide the numerical simulation method of novel high-strength steel wheel spoke pull and stretch punching combination process for passenger car, by numerical simulation method, can obtain the flowing law of metal in spoke production run, obtain the stress of part, strain, the distribution of the field variables such as wall thickness, and then just assess in advance the spoke forming property of new material steel plate before producing reality, thereby can effectively improve technological design scheme and optimize die parameters, improve spoke product quality, and by the research to process technology, guiding user makes good use of novel high-strength product made from steel, effectively reduce the rejection rate of spoke product, reduce production costs, shorten the R&D cycle, improve the market competitiveness of novel high-strength product made from steel, promote novel high-strength steel and at wheel spoke, manufacture the application and development in field.
For achieving the above object, technical scheme of the present invention is:
(1) set up spoke pull and stretch punch process three-dimensional finite element model:
1. the foundation of novel high-strength steel plate material constitutive model.Based on ABAQUS/Explicit software platform and blank shape size, set up the geometric model of plate; According to one directional tensile test, obtain the mechanical property parameters of plate, as E, K, v, σ
0.2, σ
b, n, δ etc.For the degree of impairment of research spoke forming process, need are selected suitable Ductile Fracture Criterion and are coupled in constitutive relation, thereby set up the model of material.
2. based on ABAQUS/Explicit software platform, set up the geometric model of high-strength steel spoke pull and stretch punch process.Mould is comprised of pull and stretch die, pull and stretch blank holder, punching concave die, drift, punching blank holder, punch-die (punch during pull and stretch, die during punching).
3. according to practical condition to geometric model is assembled, keep the center of each parts on an axis.
4. unit is selected to divide with grid.According to the feature of high-strength steel blank shape size, during plate division unit grid, mainly adopt C3D8R solid element to carry out discrete, this unit belongs to eight node hexahedron Reduced Integral unit, can bear larger distortion, with lower assessing the cost, obtains the higher result of precision.For taking into account finite element analogy precision and efficiency, plate and die corner contact area are carried out to mesh refinement, and sheet thickness direction is divided four-layer network lattice.In model, mould adopts R3D4 shell unit to carry out grid division, and because mould is in forming process, its cell density does not affect computational accuracy, can adopt sparse grid to carry out discrete.
5. imposed load and constraint condition, comprise the stroke of punch-die and drift and total curring time.The stroke of punch-die is determined according to the drawing height of spoke in actual production, and for avoiding dynamic effect too obvious, its amplitude curve adopts smooth transition, and the stroke of drift is determined according to assembly drawing of die, adopts displacement to load in finite element model.
6. the contact boundary condition of Definition Model.The contact of model is to comprising pull and stretch die-plate upper surface, punch-die-plate lower surface, pull and stretch blank holder-plate lower surface, drift-plate upper surface, punching blank holder-plate upper surface, totally 5 pairs of contacts are right, each contact is to adopting plane-plane contact mode, and Contact Algorithm adopts penalty function method.
(2) correctness of verification model:
Calculate deformable body kinetic energy and the ratio of interior energy and the ratio of pseudo-strain energy and interior energy in spoke drawing process, if the ratio of described kinetic energy and interior energy is no more than the numerical value of expection in forming process, can think what sheet metal deformation occurred under quasistatic, model is stable;
For the further correctness of checking computation model, the simulation result of spoke and given physical dimension are compared, if the simulation result of spoke physical dimension with to size, match, verified the correctness of the model of setting up;
If find after model energy is than unstable or simulation forming that size and intended size differ larger, return to step 1 modeling again, debugging, until model meets the demands.
(3) utilize the post-processing module of ABAQUS software, analyze wall thickness, stress, strain and the degree of impairment of spoke in spoke pull and stretch punch process, find in time the forming defects of spoke:
1. distribution and the variation of spoke equivalent stress in whole forming process are analyzed, found out its Changing Pattern, the excessive region of equivalent stress is exactly the hazardous location that spoke forming process easily produces quality problems;
2. the equivalent strain of spoke is distributed and changed and analyze, by the deformation extent of strain nephanalysis material, in spoke forming process, the approaching position of equivalent plastic strain value represents that material is close at the deformation extent at these positions, different piece deformation extent approaches, and the distortion of illustrative material is even.The region that equivalent plastic strain maximal value occurs is exactly the hazardous location that spoke is shaped; On the contrary, if spoke drip molding different piece equivalent strain differs larger, spoke forming process just easily produce that wall unevenness is even, local reduction or thicken and the phenomenon such as cracking.
3. analyze the Thickness Distribution after spoke is shaped, observe the region that occurs local excessive attenuate after spoke is shaped, the dangerouse cross-section that prediction spoke is shaped.
4. analyze damage distribution and the Changing Pattern of spoke forming process, according to damage cloud atlas, can predict the tearing tendency of spoke forming process.
(4) improve forming technology and optimize die parameters
When new material high-strength steel plate is used for spoke manufacture and occurs obvious defect, can utilize the finite element model of having set up to carry out the optimal design of technique and mould, by the modification to die, punch-nose angle and other relative dimensions in existing model, and pressure-pad-force and the friction factor of adjusting forming process, find rational forming technology and die parameters, design and be conducive to the wheel spoke processing mold that new material steel plate spoke is shaped.
The invention has the beneficial effects as follows by setting up correct finite element model, the stress of pull and stretch punch process in the time of can observing on computers novel high-strength steel plate material and produce for spoke, strain and damage distribute and situation of change, can find in time the quality problems that exist in spoke forming process, before being produced, high-strength steel spoke just can assess in advance its forming property, thereby can effectively improve technological design scheme and optimize die parameters, improve spoke product quality, avoid the defect of trial and error, and then new material is used for when spoke is manufactured reducing production costs and shortening the research and development of products cycle.And by the research to process technology, guiding user makes good use of novel high-strength Steel material, effectively reduces product rejection rate, for high-strength wheel provides foundation with steel optimization, promote the application and development of novel high-strength steel wheel.
Four, accompanying drawing explanation
Fig. 1 is the method for numerical simulation process flow diagram of high-strength steel spoke pull and stretch punching compound working procedure;
Fig. 2 is the physical dimension figure of plate of the present invention;
Fig. 3 is the true stress-true strain curve of plate material therefor B550CL of the present invention;
Fig. 4 is the geometric model figure of the present invention's wheel spoke shaping dies;
Fig. 5 is the finite element model wiring layout that the present invention's wheel spoke is shaped;
Fig. 6 is the ratio of model kinetic energy of the present invention/interior energy, pseudo-strain energy/interior energy;
Fig. 7 is spoke real profile of the present invention and analog result comparison diagram;
Fig. 8 is equivalent stress figure in spoke forming process of the present invention;
Fig. 9 is equivalent strain figure in spoke forming process of the present invention;
Figure 10 is Path figure after spoke of the present invention is shaped;
Figure 11 is along the thickness distribution figure in different paths after spoke of the present invention is shaped;
Figure 12 damages distribution plan in spoke forming process of the present invention.
Wherein: 1. concave-convex mold 2. pull and stretch blank holder 3. plate 4. punching blank holder 5. drift 6. pull and stretch dies
Below in conjunction with the drawings and specific embodiments, the present invention is conducted further description.
Five, embodiment
The present invention is a kind of method for numerical simulation of novel high-strength steel wheel spoke pull and stretch punching technology.Xian Yimou company wheel spoke pull and stretch punching technology process is object, and Mei Gang B550CL high-strength steel, as spoke material, provides specific embodiments of the invention, and its step is as follows:
Step 1, set up spoke drawing process three-dimensional finite element model:
1. the foundation of B550CL high-strength steel plate constitutive model.Based on ABAQUS software platform, set up the geometric model of plate, the physical dimension of blank as shown in Figure 2, thickness t=4.6mm.According to stretching test measurement, the elastic modulus E=172.44GPa of B550CL high-strength steel plate, Poisson ratio v=0.3, yield strength σ
0.2=349.01MPa, tensile strength sigma
b=615.89MPa, strength factor K=1048.9MPa, hardenability value n=0.20, extensibility δ=23.67%, density p=7800kg/m
3, as shown in Figure 3, its strain-stress relation is σ=1048.9 (ε+0.00227) to this material true stress-true strain curve at room temperature
0.2.For the degree of impairment of research spoke forming process, choose C-L Ductile Fracture Criterion, expression formula is
be coupled in constitutive relation subroutine and incorporation model.
2. based on ABAQUS/Explicit software platform, set up the geometric model of B550CL high-strength steel spoke pull and stretch punch process.Certain wheel spoke shaping dies is comprised of pull and stretch die, pull and stretch blank holder, punching concave die, drift, punching blank holder, punch-die (punch during pull and stretch, die during punching), and its geometric model as shown in Figure 4.
3. according to practical condition, geometric model is assembled, keep the center of each parts on an axis.
4. unit is selected to divide with grid.According to the feature of the geomery of high-strength steel blank, when carrying out division unit grid, plate mainly adopt C3D8R solid element to carry out discrete, this unit belongs to eight node hexahedron Reduced Integral unit, can bear larger distortion, with lower assessing the cost, obtains the higher result of precision.For taking into account finite element analogy precision and efficiency, plate and die corner contact area are carried out to mesh refinement, and sheet thickness direction is divided four-layer network lattice.In model, mould adopts R3D4 shell unit grid division, and because mould is in forming process, its cell density does not affect computational accuracy, can adopt sparse grid to carry out discrete.
5. imposed load and constraint condition, comprise the stroke of punch-die and drift and total curring time.According to the spoke drawing height in actual production, the total kilometres of punch-die are 91.4mm, and in finite element analogy, punching press adopts quasistatic computing method, and need to consider the stability (avoiding model to occur dynamic effect and hourglass phenomenon) of model.In actual production, the drawing velocity of mould is very fast, but when simulation need consider the conditions such as the contact, constraint of model, can stably set up, and while therefore simulating, drawing velocity is made as 50mm/s, and the time of drawing and forming is 1.828s; According to rigging position, punch stroke can be made as 6mm, and direction is contrary with drawing direction, and the time of punch process is 0.12s; According to actual production conditions, given pressure-pad-force is 5MPa.
6. the contact boundary condition of Definition Model.The contact of model is to comprising pull and stretch die-plate upper surface, punch-die-plate lower surface, pull and stretch blank holder-plate lower surface, drift-plate upper surface, punching blank holder-plate upper surface, totally 5 pairs of contacts are right, each contact is to adopting plane-plane contact mode, and Contact Algorithm adopts penalty function method; According to lubrication circumstances in spoke forming process, spoke coefficient of contact friction of each mould and plate in punching course is 0.15.
Solution based on above gordian technique, the finite element model of certain wheel spoke pull and stretch punch process of foundation as shown in Figure 5.
7. in ABAQUS software, submission task is carried out finite element analysis.
The correctness of step 2, verification model:
Calculate deformable body kinetic energy and the ratio of interior energy and the ratio of pseudo-strain energy and interior energy in spoke pull and stretch punch process, as shown in Figure 6, the ratio less (being less than 10%) of kinetic energy and interior energy in most of the time in simulation process, so in spoke forming process, there is no obvious dynamic effect; The pseudo-strain energy of this external model and the ratio of interior energy is very little (being less than 1%) also, illustrates that the hourglass situation of model is lighter, so the grid precision adopting in computation model is enough, and the finite element model of therefore setting up is reasonably stable.
For further verifying the correctness of computation model, the simulation result of spoke is compared with given physical dimension, spoke height H=96.5mm in analog result, circular arc portion diameter phi=452.8mm, aperture D=42.7mm.According to given spoke physical dimension, above-mentioned several item numbers are according to being respectively: H=96 ± 1mm, and φ=452 ± 1mm, D=42 ± 1, aperture, as shown in Figure 7.Therefore the realistic production requirement of analog result, the model of therefore setting up is correct;
Step 3, utilize the post-processing module of ABAQUS software, analyze stress, strain and degree of impairment in spoke drawing process, find in time that spoke may occur mass defect:
1. the variation of spoke equivalent stress in whole forming process is analyzed, from the equivalent stress distribution cloud atlas shown in Fig. 8, can find out, in drawing process, there is higher value at plate and die corner contact area and spoke edge, stress concentration phenomenon is obvious, if these region material structures are inhomogeneous or have a micro-crack, just there will be the defects such as cracking, illustrate that above-mentioned zone is in spoke forming process, to be prone to the region of defect.
2. the situation of change of the equivalent strain of spoke is analyzed, from the equivalent strain cloud atlas shown in Fig. 9, can be found out, the regularity of distribution and the equivalent stress of equivalent strain are basically identical.In drawing process, equivalent strain is along with pull and stretch punch travel increases and increases, but material deformation is comparatively even generally, and the fillet contact area in plate and mould outside there will be maximal value, illustrates in the distortion in this region larger; And the equivalent strain of plate between adjacent area do not undergone mutation, and seamlessly transits, illustrate that plate is out of shape evenly in forming process, so the formability of B550CL steel plate while manufacturing for certain wheel spoke is better.
3. the Thickness Distribution after spoke being shaped is analyzed, and owing to being solid of revolution after spoke drawing and forming, spoke blank edge is comprised of vertical wall section and circular arc portion, and in spoke drawing process, the material at arc-shaped edges and straight flange place flows and distinguishes to some extent.In order better to describe the Thickness Distribution rule of drip molding, on drip molding, get respectively path path1 and path2, as shown in figure 10, the outer rim in path1 path is straight portion, the outer rim in path2 path is circular arc portion.
Figure 11 shows that the rear different paths of spoke shaping lower wall thickness change rate curve, as seen from the figure, maximum reduction is about 25%, is positioned at plate and mould near the fillet contact area of spoke outer rim, is less than 30%; Maximum thickens rate and is less than 10%, is positioned at spoke edge.Therefore, after spoke drawing and forming, part there will be the attenuate of material or thickens, and these regions are all the hazardous locations that spoke is shaped, but the attenuate amount that thickens of whole spoke is in claimed range.
4. the damage regularity of distribution of spoke forming process is analyzed, as shown in figure 12, impairment value is along with punch travel increases and increases, and is evenly distributed, and only at plate and die corner contact area, has higher value; When impairment value surpasses 1, plate ftractures, and when punch stroke is 100%, plate punching place is ruptured, and realizes punching; According to damage distribution plan, there is not cracking phenomena in other parts of whole spoke.
Step 4, improvement forming technology and optimization die parameters
As can be seen from the above analysis, when being shaped for embodiment wheel spoke, there is not obvious forming defects in B550CL high strength steel plate, illustrate that this new material of B550CL can produce for this wheel spoke, so the present embodiment is not optimized improvement to forming technology and die parameters.
The above, be only embodiment of the present invention, not technical scope of the present invention imposed any restrictions, therefore any trickle modification that every technical spirit according to the present invention is done above example all belongs in the scope of technical solution of the present invention.
Claims (2)
1. a method for numerical simulation for novel high-strength steel wheel spoke pull and stretch punching compound working procedure, is characterized in that, concrete steps are as follows:
Step 1, set up the three-dimensional finite element model of spoke pull and stretch punch process:
1. the foundation of novel high-strength steel plate material constitutive model.Based on ABAQUS/Explicit software platform and blank shape size, set up the geometric model of plate; According to one directional tensile test, obtain the mechanical property parameters of plate, as E, K, v, σ
0.2, σ
b, n, δ etc.For the degree of impairment of research spoke forming process, need are selected suitable Ductile Fracture Criterion and are coupled in constitutive relation, thereby set up the constitutive model of material.
2. based on ABAQUS/Explicit software platform, set up the geometric model of high-strength steel spoke pull and stretch punch process.Mould is comprised of pull and stretch die, pull and stretch blank holder, punching concave die, drift, punching blank holder, punch-die (punch during pull and stretch, die during punching).
3. according to practical condition, geometric model is assembled, keep the center of each parts on an axis.
4. unit is selected to divide with grid.According to the feature of blank shape size, during plate division unit grid, mainly adopt C3D8R solid element to carry out discrete, this unit belongs to eight node hexahedron Reduced Integral unit, can bear larger distortion, with lower assessing the cost, obtains the higher result of precision.For taking into account finite element analogy precision and efficiency, plate and die corner contact area are carried out to mesh refinement, and sheet thickness direction is divided four-layer network lattice.In model, mould adopts R3D4 shell unit to carry out grid division, and because mould is in forming process, its cell density does not affect computational accuracy, can adopt sparse grid to carry out discrete.
5. imposed load and constraint condition, comprise the stroke of punch-die and drift and total curring time.The stroke of punch-die is determined according to the drawing height of spoke in actual production, and for avoiding dynamic effect too obvious, its amplitude curve adopts smooth transition, and the stroke of drift is determined according to assembly drawing of die, adopts displacement to load in finite element model.
6. the contact boundary condition of Definition Model.The contact of model is to comprising pull and stretch die-plate upper surface, punch-die-plate lower surface, pull and stretch blank holder-plate lower surface, drift-plate upper surface, punching blank holder-plate upper surface, totally 5 pairs of contacts are right, each contact is to adopting plane-plane contact mode, and Contact Algorithm adopts penalty function method.
The correctness of step 2, verification model:
Calculate deformable body kinetic energy and the ratio of interior energy and the ratio of pseudo-strain energy and interior energy in spoke drawing process, if the ratio of described kinetic energy and interior energy is no more than the numerical value of expection in forming process, can think that sheet metal deformation occurs under quasistatic;
For the accuracy of further verification model, spoke simulation result is compared with given physical dimension, if the simulation result of spoke physical dimension matches to size with institute, verified the correctness of the model of setting up;
If find after model energy is than unstable or simulation forming that size and intended size differ larger, return to step 1 modeling again, debugging, until model meets the demands.
Step 3, utilize the post-processing module of ABAQUS software, analyze stress, strain, Thickness Distribution and degree of impairment in spoke pull and stretch punch process, can find in time the defect that novel high-strength Steel material may occur while manufacturing for spoke:
1. distribution and the variation of spoke equivalent stress in whole forming process are analyzed, found out its Changing Pattern, the excessive region of equivalent stress is exactly the hazardous location that spoke forming process easily produces quality problems;
2. the equivalent strain of spoke is distributed and changed and analyze, by the deformation extent of strain nephanalysis material, in spoke forming process, the approaching position of equivalent plastic strain value represents that material is close at the deformation extent at these positions, different piece deformation extent approaches, and the distortion of illustrative material is even.The region that equivalent plastic strain maximal value occurs is exactly the hazardous location that spoke is shaped; On the contrary, if spoke drip molding different piece equivalent strain differs larger, spoke forming process just easily produce that wall unevenness is even, local reduction or thicken and the phenomenon such as cracking.
3. analyze spoke thickness after forming and distribute, observe spoke and whether occur local excessive attenuate, the dangerouse cross-section that prediction spoke is shaped;
4. the damage of spoke forming process is analyzed the cracking phenomena of prediction spoke forming process.
Step 4, improvement forming technology and optimization die parameters
When there is obvious defect for spoke manufacture in novel high-strength steel plate material, can utilize the finite element model of having set up to carry out the optimal design of technique and mould, by the adjustment to die corner in model and die clearance, and the pressure-pad-force and the friction factor that change forming process, find rational forming technology and die parameters, on the basis of original spoke forming technology, design and be conducive to the improvement technique that novel high-strength steel plate material spoke is shaped.
2. a kind of method for numerical simulation of novel high-strength steel wheel spoke pull and stretch punching compound working procedure as claimed in claim 1, it is characterized in that, described in step 1, select suitable Ductile Fracture Criterion and be coupled to the constitutive relation of material, need user to write voluntarily subroutine, and embed by the vumat interface of ABAQUS software.
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