CN104077439B - 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
First, technical field
The invention belongs to wheel spoke manufacture field, specifically a kind of novel high-strength steel wheel spoke drawing punching compound working procedure
Method for numerical simulation.
2nd, background technology
Wheel spoke is the main support for connecting automobile rim and wheel hub, is also the critical component of wheel safety, is manufactured
The traditional material of spoke mainly has aluminium alloy and mild steel.With auto industry to security performance and product lightweight requirements not
Disconnected to improve, high-strength steel is due to relatively low yield tensile ratio and cost lighter weight material is low in terms of safety and economy
Advantage and be widely used in spoke shaping.
Spoke stamping forming technology is made up of multiple working procedure, including drawing punching, molding, trimming, rush air holes, pressure air holes hair
Thorn etc..The first procedure shaped as spoke frequently with drawing punching compound working procedure in production, it is possible to reduce operation passage, contracting
Short total curring time, improve production efficiency simultaneously reduces production cost, is particularly suitable for producing in enormous quantities.Due to workpiece in this operation
Deflection is big, mold shape is complicated, and the wall thickness reduction even defect such as drawing crack is occurred in spoke forming process, directly influences
The final forming quality of spoke.Therefore, drawing punching operation is to determine the very important process procedure of spoke quality.
Development and the demand of auto industry with rolling mill practice, the novel high-strength steel plate material that intensity is high, shaping difficulty is big
It is more and more extensive in the manufacturing application of spoke.Novel high-strength steel plate material when shaping for spoke stamping, due to its intensity it is high,
Shaping narrow range, causes to shape difficulty big and forming quality is wayward；And when Design of Dies and process parameters design are improper,
Spoke occurs local reduction, the defect such as wall unevenness is even or even cracking.Therefore novel high-strength steel plate material is accurately predicted
The defect that is likely to occur for spoke forming process and reasonably carry out Design of Dies and Optimizing Process Parameters are for it is in automobile
Spoke is manufacturing to be promoted the use of with highly important practical significance.It is existing for high-strength steel wheel spoke stamping forming technology
Some research methoies are to rely primarily on trial-and-error method repeatedly, the shortcomings of there is cycle length, high cost, seriously constrain novel high-strength steel
Material manufactures promoting the use of for field in passenger car wheel spoke.
3rd, the content of the invention
It is an object of the invention to provide passenger car is limited with novel high-strength steel wheel spoke drawing punching combination process
First method for numerical simulation, by numerical simulation method the flowing law of metal in spoke production process can be obtained, and obtained
The distribution of the field variables such as stress, strain, wall thickness to part, and then just assess the wheel of new material steel plate in advance before produce reality
Spoke forming property such that it is able to be efficiently modified technological design scheme and optimize die parameters, improves spoke product quality, and leads to
The research to process technology is crossed, guiding user makes good use of novel high-strength product made from steel, effectively reduces the percent defective of spoke product, reduces life
Cost is produced, shortens the R＆D cycle, improve the market competitiveness of novel high-strength product made from steel, promote novel high-strength steel in wheel spoke system
Make the application and development in field.
To reach above-mentioned purpose, the technical scheme is that：
(1) spoke drawing punch process three-dimensional finite element model is set up：
1. the foundation of novel high-strength steel plate material constitutive model.Based on ABAQUS/Explicit software platforms and blank shape
Size, sets up the geometric model of plate；The mechanical property parameters of plate, including E, K, v, σ are obtained according to one directional tensile test0.2、
σb、n、δ.To study the degree of impairment of spoke forming process, suitable Ductile Fracture Criterion need to be selected and this structure is coupled it to
In relation, so as to set up the model of material.
2. ABAQUS/Explicit software platforms are based on, the geometric model of high-strength steel spoke drawing punch process is set up.Mould
Tool is made up of drawing die, drawing blank holder, punching concave die, drift, punching blank holder and punch-die, wherein, punch-die is drawing
As punch when deep, as die during punching.
3. the center of each part is kept on an axis to geometric model is assembled according to practical condition.
4. Unit selection and stress and strain model.According to the characteristics of high-strength steel blank overall dimensions, during plate division unit grid
Main to be carried out using C3D8R solid elements discrete, the unit belongs to eight node hexahedron Reduced Integral units, can bear larger
Deformation, obtain the higher result of precision with the relatively low cost that calculates.To take into account finite element modelling precision and efficiency, to plate with
Die corner contact area carries out mesh refinement, and sheet thickness direction divides four-layer network lattice.Mould adopts R3D4 shells in model
Unit carries out stress and strain model, and because mould is in forming process, its cell density does not affect computational accuracy, can adopt sparse grid
Carry out discrete.
5. imposed load and constraints, including the stroke and total curring time of punch-die and drift.The row of punch-die
Depending on drawing height of the journey according to spoke in actual production, to avoid dynamic effect too obvious, its amplitude curve is slipped over using light
Cross, the stroke of drift determines according to assembly drawing of die, is loaded using displacement in FEM (finite element) model.
6. the contact boundary condition of Definition Model.The contact of model to including drawing die-plate upper surface, punch-die-
Plate lower surface, drawing blank holder-plate lower surface, drift-plate upper surface, punching blank holder-plate upper surface, totally 5 pairs
Contact is right, respectively contacts to using plane-plane contact mode, Contact Algorithm adopts penalty function method.
(2) correctness of model is verified：
Deformable body kinetic energy and the ratio of interior energy and the ratio of pseudo- strain energy and interior energy in spoke drawing process are calculated, if institute
State kinetic energy and expected numerical value is less than in forming process with the ratio of interior energy, then it is considered that sheet metal deformation is issued in quasistatic
Raw, i.e., model is stable；
For the correctness of further checking computation model, the simulation result of spoke is compared with given overall dimensions,
If the simulation result of spoke overall dimensions matches with institute to size, the correctness of set up model is demonstrated；
If it find that model energy differs larger than size after unstable or simulation forming with intended size, then step is returned
Rapid 1 modeling, debugging again, until model meets requiring.
(3) using the post-processing module of ABAQUS softwares, analyze the wall thickness of spoke in spoke drawing punch process, stress,
Strain and degree of impairment, find in time the forming defects of spoke：
1. distribution and change to spoke equivalent stress in whole forming process is analyzed, and finds out its Changing Pattern, etc.
The excessive region of efficacy is exactly the deathtrap that spoke forming process is also easy to produce quality problems；
2. the equivalent strain of spoke is distributed and change is analyzed, by the deformation extent for straining nephanalysis material,
The close position of equivalent plastic strain value represents that deformation extent of the material at these positions is close in spoke forming process, different portions
Divide deformation extent to be close to, illustrate that the deformation of material is uniform.The region that equivalent plastic strain maximum occurs is exactly spoke shaping
Deathtrap；Conversely, if spoke drip molding different piece equivalent strain difference is larger, spoke forming process is easy for producing
Wall unevenness is even, local reduction or thicken and cracking phenomena.
3. the Thickness Distribution after spoke shaping is analyzed, the thinning region of local excessive occurs after observation spoke shaping, predicted
The dangerouse cross-section of spoke shaping.
4. the damage profile and Changing Pattern of spoke forming process are analyzed, can predicts that spoke shaped according to cloud atlas is damaged
The tearing tendency of journey.
(4) forming technology and optimization die parameters are improved：
When new material high-strength steel plate is manufactured for spoke and obvious defect occurs, it is possible to use that what is set up has
Limit meta-model carries out the optimization design of technique and mould, by die, punch-nose angle and other relative dimensions in existing model
Modification, and adjustment forming process pressure-pad-force and coefficient of friction, find rational forming technology and die parameters, design
The wheel spoke processing mold for being conducive to new material steel plate spoke to shape.
The invention has the beneficial effects as follows by setting up correct FEM (finite element) model, can on computers observe new height
The stress of drawing punch process, strain and damage profile and situation of change, can send out in time when strong steel plate material is produced for spoke
Quality problems present in existing spoke forming process, make just can in advance assess its forming property before the production of high-strength steel spoke, so as to
Technological design scheme can be efficiently modified and optimize die parameters, improve spoke product quality, it is to avoid the defect of trial-and-error method, and then
Production cost is reduced when new material is manufactured for spoke and shortens 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 percent defective, and for the optimization of high-strength wheel steel foundation is provided, and pushes away
The application and development of dynamic novel high-strength steel wheel.
4th, illustrate
Fig. 1 is the method for numerical simulation flow chart of high-strength steel spoke drawing 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 certain wheel spoke shaping dies of the invention；
Fig. 5 is the FEM (finite element) model installation diagram of certain wheel spoke shaping of the present invention；
Fig. 6 is the model kinetic energy/interior energy of the present invention, the ratio of pseudo- strain energy/interior energy；
Fig. 7 is spoke TP 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 shaping of the present invention；
Figure 11 is the thickness distribution figure in spoke shaping tailing edge difference path of the present invention；
Figure 12 is damage profile figure in spoke forming process of the present invention.
Wherein：1. the drawing die of 2. drawing blank holder of concave-convex mold, 3. plate, 4. punching blank holder, 5. drift 6.
Below in conjunction with the accompanying drawings the present invention is conducted further description with specific embodiment.
5th, specific embodiment
The present invention is a kind of method for numerical simulation of novel high-strength steel wheel spoke drawing punching technology.Now with certain company's vehicle wheel
Spoke drawing punching technology process is object, and Mei Gang B550CL high-strength steel provides the specific embodiment of the present invention as spoke material,
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.The geometry mould of plate is set up based on ABAQUS software platforms
Type, the overall dimensions of blank are as shown in Fig. 2 thickness t=4.6mm.According to stretching test measurement, the bullet of B550CL high-strength steel plates
Property modulus E=172.44GPa, Poisson's ratio v=0.3, yield strength σ0.2=349.01MPa, tensile strength sigmab=615.89MPa,
Strength factor K=1048.9MPa, hardenability value n=0.20, elongation percentage δ=23.67%, density p=7800kg/m3, the material
True stress-true strain curve at room temperature is as shown in figure 3, its strain-stress relation is σ=1048.9 (ε+0.00227)0.2。
To study the degree of impairment of spoke forming process, C-L Ductile Fracture Criterions are chosen, expression formula isCouple it to
In constitutive relation subprogram and incorporation model.
2. ABAQUS/Explicit software platforms are based on, the geometry of B550CL high-strength steel spoke drawing punch process is set up
Model.Certain wheel spoke shaping dies is by drawing die, drawing blank holder, punching concave die, drift, punching blank holder and punch-die
Composition, wherein, in drawing as punch, as die during punching, its geometric model is as shown in Figure 4 for punch-die.
3. geometric model is assembled according to practical condition, is kept the center of each part on an axis.
4. Unit selection and stress and strain model.According to the characteristics of the geomery of high-strength steel blank, plate carries out division unit
Mainly carried out using C3D8R solid elements discrete during grid, the unit belongs to eight node hexahedron Reduced Integral units, Neng Goucheng
Deformed by larger, with the relatively low cost that calculates the higher result of precision is obtained.It is right to take into account finite element modelling precision and efficiency
Plate carries out mesh refinement with die corner contact area, and sheet thickness direction divides four-layer network lattice.Mould is adopted in model
R3D4 shell unit grid divisions, because mould is in forming process, its cell density does not affect computational accuracy, can adopt sparse net
Lattice carry out discrete.
5. imposed load and constraints, including the stroke and total curring time of punch-die and drift.According to actual life
Spoke drawing height in product, the total kilometres of punch-die are 91.4mm, and in finite element modelling, punching press adopts quasistatic calculating side
Method, and the stability (avoiding model from dynamic effect and hourglass phenomenon occur) of model need to be considered.In actual production, mould
Drawing velocity is very fast, but need to consider the conditions such as contact, the constraint of model when simulating and can stably set up, therefore simulation
When drawing velocity be set to 50mm/s, the time of drawing and forming is 1.828s；According to rigging position, punch stroke can be set to 6mm, side
To with drawing direction conversely, then the time of punch process be 0.12s；According to actual production conditions, it is 5MPa to give pressure-pad-force.
6. the contact boundary condition of Definition Model.The contact of model to including drawing die-plate upper surface, punch-die-
Plate lower surface, drawing blank holder-plate lower surface, drift-plate upper surface, punching blank holder-plate upper surface, totally 5 pairs
Contact is right, respectively contacts to using plane-plane contact mode, Contact Algorithm adopts penalty function method；Feelings are lubricated according in spoke forming process
Condition, spoke each mould and coefficient of contact friction of plate in punching course are 0.15.
Based on the solution of above key technology, FEM (finite element) model such as Fig. 5 of certain wheel spoke drawing punch process of foundation
It is shown.
7. task is submitted to carry out finite element analyses in ABAQUS softwares.
The correctness of step 2, checking model：
Deformable body kinetic energy and the ratio of interior energy and the ratio of pseudo- strain energy and interior energy in spoke drawing punch process are calculated,
As shown in fig. 6, kinetic energy is less with the ratio of interior energy in the most of the time in simulation process (being less than 10%), therefore spoke shapes
During without obvious dynamic effect；The pseudo- strain energy of this external model and the ratio of interior energy also very little (being less than 1%), illustrate mould
The hourglass situation of type is lighter, therefore the grid precision adopted in computation model is enough, and the FEM (finite element) model for hence setting up is
It is stable rational.
For the correctness of further checking computation model, the simulation result of spoke is compared with given overall dimensions,
Spoke height H=96.5mm in analog result, circular arc portion diameter of phi=452.8mm, aperture D=42.7mm.According to given
Spoke overall dimensions, above-mentioned several item datas are respectively：H=96 ± 1mm, Φ=452 ± 1mm, aperture D=42 ± 1, such as Fig. 7 institutes
Show.Therefore analog result meets actual production requirement, therefore the model set up is correct.
Step 3, using the post-processing module of ABAQUS softwares, stress, strain and damage feelings in analysis spoke drawing process
Condition, finds in time the mass defect that spoke is likely to occur：
1. the change to spoke equivalent stress in whole forming process is analyzed, from the equivalent stress distribution shown in Fig. 8
As can be seen that plate has higher value, stress collection with die corner contact area and spoke border in drawing process in cloud atlas
Middle phenomenon is obvious, if these region material structures are uneven or there is micro-crack, will cracking defect, in explanation
It is the region for easily occurring defect in spoke forming process to state region.
2. the situation of change of the equivalent strain of spoke is analyzed, can from the equivalent strain cloud atlas shown in Fig. 9
Go out, the regularity of distribution of equivalent strain is basically identical with equivalent stress.In drawing process, equivalent strain is with drawing punch travel
Increase and increase, but generally material deformation is more uniform, and the rounded contact region on the outside of plate and mould occurs maximum
Value, illustrates that the deformation in this region is larger；Also, equivalent strain of the plate between adjacent area is not undergone mutation, and is
Seamlessly transit, illustrate that plate deforms uniformly in forming process, therefore B550CL steel plates are used for when certain wheel spoke is manufactured
Formability is preferable.
3. the Thickness Distribution after spoke shaping is analyzed, due to being revolving body after spoke drawing and forming, spoke blank
Edge is made up of vertical wall section and circular arc portion, and in spoke drawing process, the material flowing at arc-shaped edges and straight flange has
Distinguished.In order to preferably describe the Thickness Distribution rule of drip molding, path path1 and path2 are taken respectively on drip molding, such as
Shown in Figure 10, the outer rim in path1 paths is straight portion, and the outer rim in path2 paths is circular arc portion.
Figure 11 show different paths lower wall thickness change rate curve after spoke shaping, and as seen from the figure, maximum reduction is about
25%, positioned at plate and mould near the rounded contact region of spoke outer rim, less than 30%；Maximum thickens rate less than 10%, position
At spoke border.Therefore, the thinning of material is locally occurred after spoke drawing and forming or is thickened, these regions be all spoke into
The deathtrap of shape, but whole spoke thickens Reducing thickness in claimed range.
4. the damage profile rule of spoke forming process is analyzed, as shown in figure 12, impairment value is with punch travel
Increase and increase, and be evenly distributed, only have higher value in plate and die corner contact area；When impairment value is more than 1,
Plate ftractures, then when punch stroke is 100%, fracture is had occurred and that at plate punching, realizes punching；According to damage profile
There is no cracking phenomena in figure, whole spoke other parts.
Step 4, improvement forming technology and optimization die parameters：
As can be seen from the above analysis, B550CL high strength steel plates do not go out when certain wheel spoke shapes in for embodiment
Existing obvious forming defects, illustrates that B550CL this new material can be used for wheel spoke production, therefore the present embodiment is simultaneously
Improvement is not optimized to forming technology and die parameters.
The above, is only the embodiment of the present invention, and not the technical scope of the present invention is imposed any restrictions, therefore every
Any trickle amendment that technology according to the present invention is substantially made to above example, belongs to the scope of technical solution of the present invention
It is interior.
Claims (2)
1. a kind of method for numerical simulation of novel high-strength steel wheel spoke drawing punching compound working procedure, it is characterised in that concrete steps are such as
Under：
Step 1, the three-dimensional finite element model for setting up spoke drawing punch process：
1. the foundation of novel high-strength steel plate material constitutive model；Based on ABAQUS/Explicit software platforms and blank shape size,
Set up the geometric model of plate；The mechanical property parameters of plate are obtained according to one directional tensile test, including：Elastic modulus E, intensity
COEFFICIENT K, Poisson's ratio v, yield strength σ0.2, tensile strength sigmab, hardenability value n, elongation percentage δ, be study spoke forming process damage
Traumatic condition condition, need to select suitable Ductile Fracture Criterion and couple it in constitutive relation, so as to set up this structure mould of material
Type；
2. ABAQUS/Explicit software platforms are based on, the geometric model of high-strength steel spoke drawing punch process is set up；Mould by
Drawing die, drawing blank holder, punching concave die, drift, punching blank holder and punch-die composition, wherein, concave-convex mold is in drawing
As punch, as die during punching；
3. geometric model is assembled according to practical condition, is kept the center of each part on an axis；
4. Unit selection and stress and strain model；According to the characteristics of blank shape size, mainly adopt during plate division unit grid
C3D8R solid elements carry out discrete, and the unit belongs to eight node hexahedron Reduced Integral units, can bear larger deformation,
The higher result of precision is obtained with the relatively low cost that calculates；To take into account finite element modelling precision and efficiency, plate and mould are justified
Angular contact region carries out mesh refinement, and sheet thickness direction divides four-layer network lattice；Mould is entered using R3D4 shell units in model
Row stress and strain model, because mould is in forming process, its cell density does not affect computational accuracy, can using sparse grid carry out from
Dissipate；
5. imposed load and constraints, including the stroke and total curring time of punch-die and drift；The stroke root of punch-die
Depending on drawing height according to spoke in actual production, to avoid dynamic effect too obvious, its amplitude curve is rushed using smoothly transitting
The stroke of head is determined according to assembly drawing of die, is loaded using displacement in FEM (finite element) model；
6. the contact boundary condition of Definition Model；The contact of model is to including drawing die-plate upper surface, punch-die-plate
Lower surface, drawing blank holder-plate lower surface, drift-plate upper surface, punching blank holder-plate upper surface, totally 5 pairs of contacts
It is right, respectively contact to using plane-plane contact mode, Contact Algorithm adopts penalty function method；
The correctness of step 2, checking model：
Deformable body kinetic energy and the ratio of interior energy and the ratio of pseudo- strain energy and interior energy in spoke drawing process are calculated, if described dynamic
Expected numerical value can be less than in forming process with the ratio of interior energy, then it is assumed that sheet metal deformation is that occur under quasistatic；
For the accuracy of further checking model, spoke simulation result is compared with given overall dimensions, if spoke profile
The simulation result of size matches with institute to size, then demonstrate the correctness of set up model；
If it find that model energy differs larger than size after unstable or simulation forming with intended size, then return to step 1
Again modeling, debugging, until model meets requiring；
Step 3, using the post-processing module of ABAQUS softwares, analyze the stress in spoke drawing punch process, strain, wall thickness and divide
Cloth and degree of impairment, can in time find the defect that novel high-strength Steel material is likely to occur when manufacturing for spoke：
1. distribution and change to spoke equivalent stress in whole forming process is analyzed, and its Changing Pattern is found out, etc. effect
The excessive region of power is exactly the deathtrap that spoke forming process is also easy to produce quality problems；
2. the equivalent strain of spoke is distributed and change is analyzed, by the deformation extent for straining nephanalysis material, spoke
The close position of equivalent plastic strain value represents that deformation extent of the material at these positions is close in forming process, and different piece becomes
Shape degree is close to, and illustrates that the deformation of material is uniform；The region that equivalent plastic strain maximum occurs is exactly the danger of spoke shaping
Region；Conversely, if spoke drip molding different piece equivalent strain difference is larger, spoke forming process is easy for producing wall thickness
Uneven, local reduction thickens and cracking phenomena；
3. the distribution of spoke thickness after forming is analyzed, whether observation spoke occurs that local excessive is thinning, predicts the danger of spoke shaping
Dangerous section；
4. the damage profile of spoke forming process is analyzed, predicts the cracking phenomena of spoke forming process；
Step 4, improvement forming technology and optimization die parameters：
When novel high-strength steel plate material is used for spoke manufacture obvious defect occurs, carried out using the FEM (finite element) model set up
The optimization design of technique and mould, by the adjustment to die corner in model and die clearance, and changes forming process
Pressure-pad-force and coefficient of friction, find rational forming technology and die parameters, on the basis of original spoke forming technology, design
The modified technique for going out to be conducive to novel high-strength steel plate material spoke to shape.
2. as claimed in claim 1 a kind of method for numerical simulation of novel high-strength steel wheel spoke drawing punching compound working procedure, its feature
It is that suitable Ductile Fracture Criterion is selected described in step 1 and the constitutive relation of material is coupled it to, needs user voluntarily
Subprogram is write, and is embedded in by the vumat interfaces of ABAQUS softwares.
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