CN106709148B - Finite element simulation method for roll bending-milling process of large-size thin-walled part with step - Google Patents
Finite element simulation method for roll bending-milling process of large-size thin-walled part with step Download PDFInfo
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- CN106709148B CN106709148B CN201611051217.0A CN201611051217A CN106709148B CN 106709148 B CN106709148 B CN 106709148B CN 201611051217 A CN201611051217 A CN 201611051217A CN 106709148 B CN106709148 B CN 106709148B
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Abstract
The invention discloses a finite element simulation method for a roll bending-milling process of a large-size thin-walled part with steps. The method comprises the following steps: establishing a roll bending model of the plate, wherein the plate is an elastic plastic body, and a shell unit is adopted for carrying out grid division so as to simulate the roll bending process of the plate; simulating the trimming process by using a sub-model technology, then segmenting a region to be milled of the plate material according to the part structure of the large-size thin-walled workpiece with steps, and modifying the thickness values of shell units in different regions of the plate material so as to simulate the milling process of the large-size thin-walled workpiece with steps; the rebound process is simulated. The finite element simulation method for the roll bending-milling process of the large-size thin-walled part with the steps can accurately control the roll bending-milling process of the large-size thin-walled part with the steps, can control and even eliminate the rebound in the machining process, and avoids the defect of material performance reduction caused by means of later shaping or multiple roll bending and the like which are usually adopted at present.
Description
Technical Field
The invention relates to the field of machining and forming simulation, in particular to a finite element simulation method for a roll bending-milling process of a large-size thin-walled part with steps.
Background
In order to meet the comprehensive requirements of safety, economy, comfort and environmental protection, the novel commercial aircraft selects the light materials with small density and high specific strength such as aluminum alloy and aluminum lithium alloy on one hand and adopts a plurality of multi-step thin-wall structures such as aircraft heads, middle and rear aircraft body skins and the like on the other hand on the selection of the aircraft body materials and structures, and the multi-step thin-wall structures are formed by locally thinning skin wallboards, so that the weight of the skin wallboards can be reduced by more than 40%. The single-curvature stepped thin-wall structure is a typical light structure form of an aircraft skin panel, and is formed by roll bending a single-curvature large-size plate and subjected to milling processing to obtain the single-curvature stepped thin-wall structure.
The roll bending is a forming method which utilizes two to four roll shafts which rotate synchronously to enable plates to generate continuous plastic bending and realizes the curvature required by parts by controlling the distance between the roll shafts, and is widely applied to the manufacturing of airplane sheet metal parts. In the production of airplanes, the roll bending process is mainly used for forming single-curvature parts such as fuselage, wing skin, oil tank outer skin and the like, and after forming, redundant materials are generally removed through chemical milling or mechanical milling to achieve the aims of structural requirements and weight reduction. The skin structural member is an important part forming the aerodynamic shape of the aircraft, and bears the load and transmits the load, so that the shape precision requirement is high. However, in the roll bending process, the final curvature of the plate is affected by multiple factors such as the self performance of the material, friction, resilience and the like, the accurate control of the size is difficult, and particularly, the resilience phenomenon is more serious in the roll bending process of large-size parts. Meanwhile, in the chemical milling or mechanical milling process, due to the influence of factors such as milling shape and depth, further springback deformation can be caused, the difficulty of part manufacturing precision control is further increased, and the size precision and the production efficiency of the part are greatly influenced.
In actual production, springback is generally controlled or eliminated by means of post-forming or multiple roll bending. However, these operations lead to a reduction in material properties, and thus precise control of the springback of the skin roll-bending-milling process is of great importance for the formation of large-sized skin structural members of current aircraft. The traditional trial and error method is adopted to realize the control of the skin roll bending-milling springback, a large amount of verification tests are needed, and meanwhile, the precision is difficult to guarantee. The influence of each factor in the roll bending process on the machining precision can be comprehensively analyzed by utilizing finite element simulation to research bending forming, but the application and research of the finite element simulation technology on the integrated simulation of the roll bending and milling processes are blank. Therefore, a finite element simulation method suitable for the whole roll bending-milling process of a large-size stepped thin-wall part is urgently needed to provide effective means of simulation analysis and theoretical research for the design and the manufacture of the stepped thin-wall part, such as the design and the manufacture of an airplane skin part, so that the roll bending-milling process of the large-size stepped thin-wall part is accurately controlled, and the springback in the machining process is controlled or eliminated, so that the reduction of material performance caused by means of later-stage shape correction or multiple roll bending and the like which are usually adopted at present is avoided.
Disclosure of Invention
The invention aims to overcome the defect that the material performance of a thin-wall part is reduced by controlling the springback of a large-size thin-wall part with steps in the roll bending-milling process through means such as later shaping or multiple roll bending in the prior art, and provides a finite element simulation method for the roll bending-milling process of the large-size thin-wall part with steps.
The invention solves the technical problems through the following technical scheme:
the invention provides a finite element simulation method for a roll bending-milling process of a large-size thin-walled part with steps, which is characterized by comprising the following steps of:
step one, establishing a roll bending model of a plate, wherein the plate is an elastic plastic body, and a linear shrinkage integral shell unit is adopted for grid division, the roll bending model is used for simulating the roll bending process of the plate, and the roll bending process comprises bending, roll bending and springback of the plate;
simulating a result after the roll bending process based on the roll bending model, and simulating a trimming process by using a sub-model technology, wherein the trimming process removes the edge straight part of the plate and reserves a middle uniform deformation region, then dividing regions to be milled of the plate according to the part structure of the large-size thin-walled workpiece with steps, and modifying the thickness values of shell units in different regions of the plate so as to simulate the milling process of the large-size thin-walled workpiece with steps;
and step three, simulating a rebound process based on the workpiece obtained by simulating the milling process in the step two, wherein the simulation of the rebound process comprises closing a vacuum adsorption system to enable the milled workpiece to be in an unconstrained free deformation state on a vacuum platform, selecting five crossed points at the center of the plate material on the bottom surface of the workpiece, and constraining the displacement and rotation of the five points to perform rebound calculation after the plate material is milled, wherein the constraint conditions of the five points are that the central point is completely fixed, and the other four points are constrained to reduce the influence on the rebound deformation to the maximum extent.
Preferably, the constraint conditions for the other four points except the center point of the five points are as follows:
two points distributed in a first axial direction relative to the central point, wherein the second axial translational freedom degree and the rotation freedom degrees around the first axial direction and the third axial direction are restrained;
two points distributed in a second axial direction relative to the central point, the first axial translational degree of freedom and the second axial rotational degree of freedom and the third axial rotational degree of freedom of the two points are restrained;
the first axial direction, the second axial direction and the third axial direction are mutually vertical, and the second axial direction is the direction of roll bending of the plate material.
Preferably, in the step one, a discrete rigid body is adopted to model an upper roller and two lower rollers as parts which are contacted and extruded with the plate, and the movement of the rollers is controlled according to the roll bending forming process of the large-size thin-walled part with steps, so as to simulate the roll bending process.
Preferably, the simulation of the roll bending process comprises the following three analysis steps:
the method comprises the following steps that firstly, an upper roller is pressed downwards to bend a plate, and the bending radius of a roll bending process is controlled by adjusting the pressing amount of the upper roller;
secondly, keeping the pressing state of the upper roller unchanged, rotating the upper roller, realizing roll bending of the plate through frictional contact with the plate, enabling the plate to start roll bending from one side edge by the following of the lower roller, reversing the upper roller after the plate is roll bent to the other side edge, and returning to the starting position of the pressing state to stop;
and thirdly, stopping roll bending, lifting the upper roller and rebounding the plate.
Preferably, in the step one, hourglass rigidity enhancement control is started to avoid hourglass of the plate material in the roll bending process.
Preferably, the finite element simulation method is implemented by ABAQUS software.
Preferably, the calculation in the first step is performed by using Explicit algorithm Explicit.
Preferably, a static implicit algorithm is adopted in the third step to simulate the rebound process.
Preferably, the large-size stepped thin-wall part is a single-curvature stepped thin-wall part.
On the basis of the common knowledge in the field, the above preferred conditions can be combined randomly to obtain the preferred embodiments of the invention.
The positive progress effects of the invention are as follows:
the finite element simulation method for the roll bending-milling process of the large-size thin-walled part with the steps can accurately control the roll bending-milling process of the large-size thin-walled part with the steps, can control and even eliminate the rebound in the machining process, and avoids the defect of material performance reduction caused by means of later shaping or multiple roll bending and the like which are usually adopted at present.
Drawings
FIG. 1 is a flow chart of a finite element simulation method of a roll bending-milling process of a large-size stepped thin-walled workpiece according to a preferred embodiment of the invention;
FIG. 2 is a schematic diagram of an initial state of a roll bending model of a sheet material in a finite element simulation method according to a preferred embodiment of the present invention;
FIG. 3 is a schematic illustration of an hourglass problem that may occur in finite element simulations;
FIG. 4 is a schematic diagram of a part after milling and trimming the sheet material in the finite element simulation method according to a preferred embodiment of the present invention;
FIG. 5 is a schematic diagram of five-point constraint of rebound after milling in a finite element simulation method according to a preferred embodiment of the present invention;
Detailed Description
The following detailed description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings, is intended to be illustrative, and not restrictive, and it is intended that all such modifications and equivalents be included within the scope of the present invention.
In the following detailed description, directional terms, such as "left", "right", "upper", "lower", "front", "rear", and the like, are used with reference to the orientation as illustrated in the drawings. Components of embodiments of the present invention can be positioned in a number of different orientations and the directional terminology is used for purposes of illustration and is in no way limiting.
Referring to fig. 1, a finite element simulation method for roll bending-milling process of a large-size stepped thin-walled workpiece according to a preferred embodiment of the invention includes the following steps:
step one, establishing a roll bending model of a plate, wherein the plate is an elastic plastic body, and a linear shrinkage integral shell unit is adopted for grid division, the roll bending model is used for simulating the roll bending process of the plate, and the roll bending process comprises bending, roll bending and springback of the plate;
simulating a result after the roll bending process based on the roll bending model, and simulating a trimming process by using a sub-model technology, wherein the trimming process removes the edge straight part of the plate and reserves a middle uniform deformation region, then dividing regions to be milled of the plate according to the part structure of the large-size thin-walled workpiece with steps, and modifying the thickness values of shell units in different regions of the plate so as to simulate the milling process of the large-size thin-walled workpiece with steps;
and step three, simulating a rebound process based on the workpiece obtained by simulating the milling process in the step two, wherein the simulation of the rebound process comprises closing a vacuum adsorption system to enable the milled workpiece to be in an unconstrained free deformation state on a vacuum platform, selecting five crossed points at the center of the plate material on the bottom surface of the workpiece, and constraining the displacement and rotation of the five points to perform rebound calculation after the plate material is milled, wherein the constraint conditions of the five points are that the central point is completely fixed, and the other four points are constrained to reduce the influence on the rebound deformation to the maximum extent.
It should be understood that the springback of the sheet material involved in step one and the springback involved in step three are different springbacks that occur successively during the machining of the roll bending-milling process. The former time is springback in the roll bending process, and the latter time is further springback caused by the influences of factors such as milling depth, shape and the like in the milling and milling processes.
The accuracy of finite element simulation in a part machining process has a direct relationship with the establishment of a finite element model and the establishment of boundary conditions, but those skilled in the art will understand that the boundary conditions can be generally determined by the specific machining requirements, the part dimensions, and the like of the part machining process that the finite element simulation attempts to simulate, and further description is omitted here. For the roll bending-milling process of the large-size thin-walled part with the step, roll bending and milling are two important processes of a forming process, so that a roll bending model and a milling model are important components in the technical scheme of the invention, and the establishment of the two models and the related simulation and operation can be generally corresponding to the first step and the second step of the invention. The finite element simulation method of the roll bending-milling process of the large-size stepped thin-walled part of the invention is illustrated in more detail below.
In a preferred embodiment of the present invention, the above step may specifically include the following steps. For example, referring to fig. 2, a model may be created according to the structure and size of a three-axis sheet bending machine, in which three rollers are used as main components for contact and pressing with the sheet 3, and the three rollers are modeled using discrete rigid bodies regardless of their deformation. The parameters used in the modeling include the radius r1 of the upper roller 1, the radius r2 of the two lower rollers 2, and the distance L between the lower rollers 2. The plate 3 is modeled into an elastic plastic body, a linear reduction integral shell unit S4R is selected for grid division, hourglass rigidity enhancement control is started, and hourglass appearance of the plate in the roll bending process is prevented. A possible hourglass defect is shown in fig. 3. The plate is arranged between the upper roller and the lower roller, and the movement of the rollers is controlled according to the actual process of roll bending forming, so that the roll bending process is realized.
Specifically, the roll bending process can be simulated by establishing the following three analysis steps: firstly, pressing down an upper roller 1 to bend a plate 3, and controlling the bending radius in the roll bending process by adjusting the pressing-down quantity H (shown in figure 2) of the upper roller 1; secondly, the upper roller 1 keeps a pressing state still, the upper roller 1 rotates automatically, the sheet 3 is rolled and bent through frictional contact with the sheet 3, the lower roller 2 follows up, the sheet 3 starts to be rolled and bent from one side edge, the upper roller 1 rotates reversely after the sheet 3 is rolled and bent to the other side edge, and the sheet is returned to the starting position of pressing and stopped; and thirdly, after the roll bending is finished, the upper roller 1 rises, and the plate 3 rebounds. The specific calculation and simulation of the roll bending process can be calculated using an Explicit algorithm, Explicit, such as the ABAQUS software.
In the preferred embodiment of the present invention, the above step two is adopted to complete the simulation of trimming and milling of the local sub-model. The milled wall panel is shown in fig. 4, and step two may specifically include the following process.
In the milling simulation model, because the simulation process is based on the simulation result of roll bending, the milling simulation model only needs to establish a finite element model of the blank separately. Redefining the size of the blank based on the characteristics of the sub-model and the structural size of the milled part to enable the size of the blank to be consistent with the size of the part after trimming; and meanwhile, the plate is divided, the area needing milling is divided, and the thickness of the area is redefined to be consistent with the thickness distribution of the actually milled blank. And finally, by a sub-model recalculation technology, recalculating the sub-model of the simulation result of the roll bending model in the plate with the modified structure, completing the transmission of the roll bending simulation result and realizing the simulation of the milling process.
Through the steps, the reserved part of the plate after the simulated trimming is used as a local submodel, and the thickness values of the shell units corresponding to different regions of the thin-wall structure with the steps are modified to simulate the milling process, so that the simulated result of the milled part obtained through simulation is obtained.
In the preferred embodiment of the invention, the springback of the part material after milling is simulated by adopting the third step. Specifically, based on the milling simulation result in the step two, the milling simulation result is transferred to the springback simulation model in a predefined field mode. Because the blank rebound process only relates to the redistribution of the internal stress of the blank, the rebound simulation model only needs to establish a blank model, and the size and the structure of the blank in the rebound simulation model are consistent with the size of the blank in the milling simulation model based on the predefined field and the rebound characteristics. And the springback process in the third step adopts a static implicit algorithm to complete the simulation.
The selection of the clamping position in the unloading rebound process is a key, in the actual processing, the vacuum adsorption system is closed after the milling is finished, so that the workpiece is in an unconstrained free deformation state on a vacuum platform, all constraints in the front are cancelled at the moment, meanwhile, five crossed points in the center of the plate are selected on the bottom surface of the workpiece in order to eliminate rigid displacement of the workpiece by combining the rebound simulation characteristics, as shown in fig. 5, the displacement and the rotation of the five crossed points are constrained, wherein only the central point adopts completely fixed constraint, and the constraint principle of other points is that the constraint of the points reduces the influence on the rebound deformation to the maximum extent. For example, referring to fig. 5, the constraints for the five points are: the center point is completely fixed; two points distributed in the X-axis direction relative to the central point are constrained in the translation freedom degree in the Y-axis direction and the rotation freedom degrees in the X-axis direction and the Z-axis direction; two points distributed in the Y-axis direction relative to the central point are constrained in the translation freedom degree in the X-axis direction and the rotation freedom degrees in the Y-axis direction and the Z-axis direction; the X-axis direction, the Y-axis direction and the Z-axis direction are mutually vertical, and the Y-axis direction is the direction of roll bending of the plate. That is, the boundary condition between two points in the X direction of the center point may be U2 ═ UR1 ═ UR3 ═ 0, and the boundary condition between two points in the Y direction of the center point may be U1 ═ UR2 ═ UR3 ═ 0. Where U represents a translational degree of freedom, UR represents a rotational degree of freedom, and 1, 2, and 3 represent X, Y, Z-axis directions, respectively. The boundary conditions are used for restraining the displacement in the direction perpendicular to the roll bending feeding direction of the plate and the rotational degrees of freedom in the other two directions except the rotational direction of the idler wheel, restraining the displacement and rotation of five points, and realizing the springback of the plate after edge cutting and milling.
The finite element simulation method of the roll bending-milling process of the large-size thin-walled part with the steps fully utilizes some characteristics of the roll bending-milling process of the large-size thin-walled part with the steps to improve the efficiency of the finite element simulation method and ensure the accuracy of the finite element simulation method at the same time
Firstly, taking a roll bending model as an example, the establishment of the roll bending model is to accurately shift the residual stress and the rebound after roll bending into a milling model so as to realize the accurate description of the rebound caused by stress release and redistribution after material removal, and simultaneously, as the main deformation area in the roll bending process is concentrated at the middle part of a plate material and the curvatures at the front edge and the rear edge along the feeding direction are very small, after the roll bending deformation of a large-size plate material is finished, the invention removes the edge straight part by trimming, reserves the middle uniform deformation area, and realizes the simulation of the trimming process by a sub-model technology
Secondly, since the milling process is a process involving many complex physical phenomena such as deformation, fracture, dynamics, nonlinear contact, heat conduction, and the like, and also involving many links of process systems such as machine tools, fixtures, workpieces, and the like, it is very difficult to establish an accurate simulation model of the milling process, and it is usually necessary to simplify the complex physical conditions to a certain extent on the premise of ensuring the accuracy of the analysis result. In terms of the invention, the invention utilizes that the large-size stepped thin-wall part is generally close to the single-curvature stepped thin-wall part, the milling amount is small in the milling process, the milling force is small, so the generated milling heat is small, the cutting fluid is usually used for cooling all the time in the machining process, the cooling effect is good, the influence of the milling heat is neglected in the invention, meanwhile, the influence of the strain rate can also be neglected, so an elastic-plastic material model is used.
In addition, for the body unit model, a typical material removal mode is a unit life and death technology, but the defects of low calculation efficiency and easiness in generation of an hourglass phenomenon exist in the process of calculating the roll bending model by using the body unit, so that the shell unit is adopted for simulation in the invention, the thickness values of the shell units in different areas of the stepped thin-wall structure are modified, and the milling simulation is completed by combining a sub-model recalculation technology. The method greatly improves the calculation efficiency and saves the calculation cost while ensuring the calculation accuracy.
While specific embodiments of the invention have been described above, it will be appreciated by those skilled in the art that these are by way of example only, and that the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the spirit and scope of the invention, and these changes and modifications are within the scope of the invention.
Claims (8)
1. A finite element simulation method for a roll bending-milling process of a large-size thin-walled part with steps is characterized by comprising the following steps of:
step one, establishing a roll bending model of a plate, wherein the plate is an elastic plastic body, and a linear shrinkage integral shell unit is adopted for grid division, the roll bending model is used for simulating the roll bending process of the plate, and the roll bending process comprises bending, roll bending and springback of the plate;
simulating a result after the roll bending process based on the roll bending model, and simulating a trimming process by using a sub-model technology, wherein the trimming process removes the edge straight part of the plate and reserves a middle uniform deformation region, then dividing regions to be milled of the plate according to the part structure of the large-size thin-walled workpiece with steps, and modifying the thickness values of shell units in different regions of the plate so as to simulate the milling process of the large-size thin-walled workpiece with steps;
step three, simulating a rebound process based on the workpiece obtained by simulating the milling process in the step two, wherein the simulation of the rebound process comprises closing a vacuum adsorption system to enable the milled workpiece to be in an unconstrained free deformation state on a vacuum platform, selecting five crossed points at the center of the plate material on the bottom surface of the workpiece, and constraining the displacement and rotation of the five points to perform rebound calculation after the plate material is milled, wherein the constraint conditions of the five points are that the central point is completely fixed, and the constraint conditions of other four points are as follows:
two points distributed in a first axial direction relative to the central point, wherein the second axial translational freedom degree and the rotation freedom degrees around the first axial direction and the third axial direction are restrained;
two points distributed in a second axial direction relative to the central point, the first axial translational degree of freedom and the second axial rotational degree of freedom and the third axial rotational degree of freedom of the two points are restrained;
the first axial direction, the second axial direction and the third axial direction are mutually vertical, and the second axial direction is the direction of roll bending of the plate material.
2. The finite element simulation method of claim 1, wherein in the first step, one upper roller and two lower rollers are modeled by discrete rigid bodies as parts contacting and extruding with the sheet material, and the movement of the rollers is controlled according to the roll bending forming process of the large-size thin-walled part with steps to simulate the roll bending process.
3. A finite element simulation method according to claim 2, wherein the simulation of the roll bending process comprises the following three analysis steps:
the method comprises the following steps that firstly, an upper roller is pressed downwards to bend a plate, and the bending radius of a roll bending process is controlled by adjusting the pressing amount of the upper roller;
secondly, keeping the pressing state of the upper roller unchanged, rotating the upper roller, realizing roll bending of the plate through frictional contact with the plate, enabling the plate to start roll bending from one side edge by the following of the lower roller, reversing the upper roller after the plate is roll bent to the other side edge, and returning to the starting position of the pressing state to stop;
and thirdly, stopping roll bending, lifting the upper roller and rebounding the plate.
4. A finite element simulation method as claimed in claim 1, wherein in step one, hourglass stiffness enhancement control is turned on to avoid hourglass in the panel during roll bending.
5. A finite element simulation method as claimed in claim 1, wherein the finite element simulation method is implemented using ABAQUS software.
6. A finite element simulation method according to claim 5, wherein the calculation in step one is performed using Explicit algorithm Explicit.
7. A finite element simulation method according to claim 5, wherein in step three, a static implicit algorithm is used to simulate the springback process.
8. The finite element simulation method of claim 1, wherein the large-sized stepped thin-walled part is a single-curvature stepped thin-walled part.
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| CN112058961B (en) * | 2020-08-20 | 2022-02-11 | 中国商用飞机有限责任公司 | Method, apparatus and medium for roll forming of monolithic wall panels |
| CN114429065B (en) * | 2022-01-07 | 2024-02-23 | 西北工业大学 | Method for calibrating rebound of contact material of rear tool face in micro-milling process based on finite element |
| CN115091129B (en) * | 2022-06-22 | 2023-07-25 | 四川航天长征装备制造有限公司 | Rolling bending and shape correcting process method for aluminum alloy wallboard |
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