CN107363142B - Hot stamping forming control method of composite metal plate - Google Patents
Hot stamping forming control method of composite metal plate Download PDFInfo
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- CN107363142B CN107363142B CN201610318628.5A CN201610318628A CN107363142B CN 107363142 B CN107363142 B CN 107363142B CN 201610318628 A CN201610318628 A CN 201610318628A CN 107363142 B CN107363142 B CN 107363142B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/16—Heating or cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/20—Making tools by operations not covered by a single other subclass
Abstract
A hot stamping forming control method of a composite metal plate, in particular to a hot stamping forming control method for improving the high-temperature hot stamping forming efficiency and precision of the composite metal plate, which comprises the following steps: establishing a finite element model of the composite metal plate, and optimizing the finite element model to enable the finite element model to meet the requirements; correcting the finite element model of the die for processing the formed part according to the established finite element model of the composite metal plate; and casting a solid die by using the die finite element model meeting the requirements, and carrying out hot stamping on the composite metal plate by using the solid die. The method can improve the one-time qualification rate of the hot stamping forming part of the composite metal plate and improve the forming processing efficiency and precision of the material.
Description
Technical Field
The invention relates to a hot stamping forming control method of a composite metal plate, in particular to a hot stamping forming control method for improving the high-temperature hot stamping forming efficiency and precision of the composite metal plate.
Background
The large reaction vessel used in the chemical industry requires that the material has both strong corrosion resistance and high mechanical strength. The thickness of the plate material generally used is large, usually 60-80mm, even more than 100mm, and if stainless steel is used as the raw material for manufacturing these large reaction vessels, the cost is very high. Therefore, the industry often uses a double-layer composite metal plate (formed by compounding a layer of stainless steel and a layer of carbon steel) of different materials to replace the stainless steel to manufacture the reaction vessel. The composite metal plate is formed by welding a layer of stainless steel and a layer of carbon steel together by a special method, and can not be separated in the later processing and forming process and can be always kept as a whole (the production method of the composite metal plate is out of the discussion range of the invention). The reaction vessel produced by the composite metal plate not only has the corrosion resistance effect of stainless steel, but also has high mechanical strength and low cost.
However, the stamping forming of the composite metal plate is a difficult point, particularly, the composite metal plate with a thicker thickness must be formed by a hot stamping mode, and the formed part has larger deformation and lower forming precision due to the influence of expansion and contraction, phase change and the like in the cooling process after the forming, so that the later processing of the reaction vessel is directly influenced. For example, the top cover of a reactor vessel is relatively large, typically several meters in diameter (as shown in fig. 8), and is generally formed by first dividing the top cover into several parts, then forming each part separately, and finally splicing and welding all the formed parts (as shown in fig. 9) into a large top cover. If the precision of each formed part is poor, steps exist among different formed parts in the assembling and welding process, metal welding of the same material cannot be realized, and the corrosion resistance and the strength are influenced. At present, the one-time yield of the hot stamping of the thick composite metal plate is almost zero, the design size requirement can be met only by repeatedly stamping and correcting the thick composite metal plate for several times at a medium temperature (400 ℃ -500 ℃) after the thick composite metal plate is subjected to hot stamping at a high temperature (about 900 ℃), and some thick composite metal plates are even scrapped because the thick composite metal plate cannot be corrected to the required shape. Therefore, it is very important to effectively improve the high-temperature hot stamping forming precision of the thick composite metal plate.
In the prior patents, how to hot press high-strength steel is described, but the hot-pressing method is generally applied to a steel plate made of a single material and has a small thickness, which is usually less than 10 mm. No relevant patent researches the hot stamping forming processing problem of the composite thick metal plate. In patent document 1, there are provided an ultrahigh-strength steel hot stamping forming process and a forming die, wherein before the ultrahigh-strength steel plate material is subjected to hot stamping forming, the hot stamping forming process heats the parts which are in contact with the ultrahigh-strength steel plate material in the die involved in stamping, so that the surface temperature of the parts reaches above the martensite point temperature of the ultrahigh-strength steel, and then the ultrahigh-strength steel plate material heated to be completely austenitized is placed in the die for stamping forming, after the hot stamping die is closed, the die is cooled, and the forming member is quenched by the die parts which are in contact with the forming member. Patent document 1 avoids the occurrence of cracks on the surface and inside of the molded part, eliminates the molding rebound of the member, and ensures the precision and quality of the product. The method allows the formed part to be quenched and cooled in the die cavity, and is suitable for forming thin members. However, for a member having a too large thickness, the quenching cooling to a low temperature in the cavity closed by the upper and lower molds is not applicable. This is because the thickness of the member is large, the difference in cooling rate between the inside and outside of the plate material during molding is large, and cracks are generated on the surface and inside of the molded article, and the molding resilience of the member having a large thickness during cooling is large, and the resilience may damage the closed mold.
Patent document
Patent document 1: CN101439382A
Disclosure of Invention
The forming object of the invention is a metal plate with larger thickness, the general thickness is larger than 60mm, and the invention is a composite metal plate formed by compounding two layers of different metal materials, the difference of the cooling speed inside and outside the plate is larger when forming, the expansion caused by heat and the contraction caused by cold need to release large stress, and the forming precision is difficult to be ensured.
The invention aims to provide a hot stamping forming control method of a composite metal plate, which can improve the high-temperature hot stamping forming efficiency and precision of the composite metal plate.
The invention relates to a hot stamping forming control method of a composite metal plate, which comprises the following steps:
(1) establishing a finite element model of the existing hot stamping die according to the existing hot stamping die, establishing a finite element model of the composite metal plate according to the raw material size of an actual formed part manufactured by the existing hot stamping die, dividing a grid of the finite element model of the composite metal plate, inputting material performance parameters of each material of the composite metal plate obtained in advance into the finite element model of the composite metal plate, simulating the hot stamping forming and cooling processes of the composite metal plate by using the finite element model of the existing hot stamping die and the finite element model of the composite metal plate input with the material performance parameters, simulating a cooled first simulated formed part size according to the total strain obtained by the material performance parameters, and comparing the first simulated formed part size with the actual formed part size, under the condition that the error is smaller than or equal to a first threshold value, the finite element model of the composite metal plate meets the requirement, under the condition that the error exceeds the first threshold value, the grid of the finite element model of the composite metal plate is refined, and the simulation is carried out again until the error is smaller than or equal to the first threshold value;
(2) establishing a finite element model of a new hot stamping die according to the design size of a formed part to be processed, simulating the hot stamping forming and cooling process of the composite metal plate by combining the finite element model of the composite metal plate meeting the requirement, simulating to obtain the size of a second simulated formed part after cooling, comparing the size of the second simulated formed part with the design size, wherein the finite element model of the new hot stamping die meets the requirement under the condition that the error is less than or equal to a second threshold value, modifying the finite element model of the new hot stamping die under the condition that the error exceeds the second threshold value, and simulating again until the error is less than or equal to the second threshold value;
(3) and casting a solid die by using the finite element model of the new hot stamping die meeting the requirements, and carrying out hot stamping on the composite metal plate by using the solid die.
According to the invention, the forming requirements of metal plates with different materials and different thicknesses can be met, the one-time qualification rate of the hot stamping formed part of the composite metal plate is improved, the high-temperature hot stamping forming efficiency and precision of the composite metal plate are effectively improved, and a product meeting the precision requirement is rapidly processed.
Drawings
FIG. 1 is a flow chart illustrating the creation of a finite element model of a composite metal sheet.
FIG. 2 is a flow chart showing a finite element model for modifying a new hot stamping die for a formed part to be machined.
Fig. 3 is a flowchart showing press forming using a solid mold.
Fig. 4A is a schematic view showing a finite element model of the composite metal sheet before meshing, and fig. 4B is a schematic view showing a finite element model of the composite metal sheet after meshing.
Fig. 5 is a schematic view showing a preset mold.
Fig. 6 is a diagram showing the relationship between the error between the dimension of the second dummy molded article obtained by the simulation and the design required dimension and the number of times of die correction.
Fig. 7 is a schematic view showing the molded article after press cooling.
Fig. 8 is a schematic view showing a top cover of the reactor vessel.
Fig. 9 is a schematic view showing a part obtained by dividing the top cover into equal parts.
Detailed Description
The following describes a specific embodiment of the present invention with reference to the drawings. However, the technical scope of the present application is not limited to the following embodiments, and includes inventions described in claims and equivalents thereof.
(1) Establishing a finite element model of the composite metal plate, and optimizing the finite element model to meet the requirements
FIG. 1 is a flow chart illustrating the creation of a finite element model of a composite metal sheet. The process of establishing a finite element model of a composite metal sheet is described below with reference to fig. 1.
First, the mechanical properties, linear expansion coefficient, thermal conductivity and specific heat capacity of materials of different materials at different temperatures were measured (S11). In the present example, the inventors have studied a clad metal plate having a total plate thickness of 105mm, which is formed by compounding SUS304 stainless steel having a thickness of 5mm and Q345R steel plate having a thickness of 100 mm. And (3) performing tensile tests on the SUS304 and the Q345R by using a SHIMADZU universal tensile testing machine at different temperatures to obtain a load displacement curve of the material, and calculating a flow stress curve and corresponding mechanical property parameters at different temperatures. In addition, thermal conductivity, linear expansion coefficient and specific heat capacity of SUS304 and Q345R at different temperatures were measured, respectively. The mechanical properties, linear expansion coefficient, thermal conductivity and specific heat capacity of the materials of different materials measured in advance at different temperatures are used as material performance parameters of each material of the composite metal plate, and specific examples of the material performance parameters are shown in table 1 below. In addition, the material performance parameters can also include known conventional parameters such as the density of the material.
TABLE 1
Then, from the existing hot stamping die, a finite element model of the existing hot stamping die is created (S12), and the hot stamping die is defined as a rigid body, i.e., non-deformable. Then, a finite element model of the composite metal plate is created based on the raw material size of the actual formed part manufactured by the conventional hot stamping die (S12), and the finite element model of the composite metal plate is shown in fig. 4A. As shown in fig. 4B, the upper and lower layers of metal of the composite metal plate are respectively divided into finite element meshes, and the material performance parameters of each material of the composite metal plate obtained in advance are input into the finite element model of the composite metal plate (S13). The contact surface between the two layers of metal plates made of different metal materials is set to be in a combined state, so that the upper layer metal plate and the lower layer metal plate deform together when the composite metal plate deforms, and the upper layer metal plate and the lower layer metal plate do not disengage in the deformation process. In fig. 4A and 4B, the upper layer represents a Q345R steel plate, and the lower layer represents a SUS304 stainless steel plate.
Then, the hot press forming and cooling process of the composite metal sheet is simulated using the finite element model of the existing hot press mold and the finite element model of the composite metal sheet inputted with the material property parameters (S14). Specifically, hot stamping simulation is carried out on the composite metal plate at the temperature of 900 ℃ to obtain a hot stamped formed part, then the process that the formed part is rapidly cooled to room temperature from high-temperature water spraying is continuously simulated, and the size of the formed and cooled part is predicted. The deformation simulation in the cooling process needs to consider the influence of expansion and contraction of the material and the phase change on the size. The total strain associated with deformation is assumed to be due to thermal strain
Elastic strain
Plastic strain
Strain of phase change
And transformation plasticity
The total strain can then be calculated by the following equation (1):
wherein thermal strain
Elastic strain
Plastic strain
Strain of phase change
And transformation plasticity
The material property parameters are automatically calculated by inputting the material property parameters into a finite element model.
That is, the first dummy molded article size after cooling was obtained by simulation based on the total strain obtained from the material property parameters (S14).
Next, in order to verify the accuracy of the finite element model of the composite metal plate created, the simulated first modeled dimension and the actual press-formed dimension of the existing die are compared (S15), and if the error between the two is within a set range (for example, set to 1%) in step S16, the accuracy of the finite element model of the composite metal plate is considered to be satisfactory. If the simulation accuracy is not sufficient, the finite element model of the composite metal plate is optimized, for example, the mesh size is reasonably refined (S17), and the step S14 is returned to, and the simulation is performed again. And repeating the processes of optimization, simulation and comparison until the error between the two is within a set range.
In the embodiment, the finite element model of the composite metal plate is refined, and the influence of the size of the finite element grid in the thickness direction of the plate on the simulation precision is large, the precision is high when the grid in the thickness direction is thinner, but the simulation time is long when the grid is too thin. Therefore, the mesh size in the thickness direction of the stainless steel layer of the composite metal plate in this example is 1/3 of its thickness, and the mesh size in the thickness direction of the carbon steel layer is 1/7 of its thickness, as shown in fig. 4B.
(2) Correcting the finite element model of the new hot stamping die for processing the formed part according to the finite element model of the built composite metal plate
FIG. 2 is a flow chart showing a finite element model for modifying a new hot stamping die for a formed part to be machined. The following describes a procedure for correcting a finite element model of a new hot stamping die for a formed part with reference to fig. 2.
First, a finite element model of a new hot stamping die, an example of which is shown in fig. 5, is preliminarily set up according to the design size of a formed part to be processed (S21), and the die is defined as a rigid body, i.e., non-deformable. And (3) combining the finite element model of the composite metal plate which is established in the previous step and meets the requirements, performing hot stamping simulation on the composite metal plate at the temperature of 900 ℃ to obtain a formed part after hot stamping, then continuing simulating the process of rapidly cooling the formed part from high-temperature water spraying to room temperature (the specific simulation process is the same as the previous step), and simulating to obtain the size of a second formed part after forming and cooling (S22).
Then, the dimension of the second modeled molded article obtained by the simulation is compared with the design requirement dimension of the molded article (S23), and if the error between the two is within the set range (for example, set to 1%) in step S24, it indicates that the molded article hot stamped by using the new hot stamping die satisfies the accuracy requirement, and the finite element model of the new hot stamping die satisfies the requirement. If the error between the two is beyond the set range (for example, set to 1%), the formed part punched by the new hot stamping die is considered to be not satisfactory. The computer automatically makes an optimization correction to the 3D shape of the finite element model of the new hot stamping die (S25), for example: and if the size of the second simulated formed part obtained by simulation is larger than the design requirement, reducing the size of the new hot stamping die by a corresponding amount, and if the size of the second simulated formed part obtained by simulation is smaller than the design requirement, amplifying the size of the new hot stamping die by a corresponding amount. Then, returning to step S22, the stamping and cooling process simulation is performed again, and the simulated second simulated molded part size is compared with the design required size of the molded part again. And repeating the processes of correction, simulation and comparison until the error between the dimension of the second simulated formed part obtained by simulation and the design required dimension of the formed part is in a set range, and determining that the finite element model of the new hot stamping die meets the requirement. In this embodiment, the shape of the new hot stamping die is modified after 4 times, and the dimension error between the dimension of the formed part after stamping and cooling and the design requirement is less than 1%, which meets the requirement, as shown in fig. 6.
(3) Casting a solid die by using a finite element model of a new hot stamping die meeting the requirements, and carrying out hot stamping on the composite metal plate by using the solid die
Fig. 3 is a flowchart showing press forming using a solid mold. Next, a flow of press forming by a solid mold will be described with reference to fig. 3.
Casting a desired solid mold according to the new hot stamping mold 3D size output from the previous step (S31). The clad metal sheet is preheated to 900 deg.c (S32) in a vacuum furnace, and the mold is preheated to an appropriate temperature (S33). The mold is fixed to a hydraulic press, the clad metal sheet is placed in the mold for hot stamping using a crane, and then the upper mold is removed and quenched to room temperature by water spray (S34). The press-formed cooled molded article is shown in fig. 7. The actual dimensions of the molded article after molding cooling are measured and compared with the design requirement dimensions (S35). In step S36, if the molded article size satisfies the error requirement (for example, set to 1%), it is determined to be a non-defective product. If the error is certain, the formed part is put back to the vacuum furnace to be heated to about 450 ℃ (S37), then the step is returned to S34, medium-temperature stamping is carried out to correct the shape, the size is measured after water spraying and cooling, and the size is compared with the size required by design until the error meets the requirement.
Through practical verification, the method can ensure that the primary qualified rate (without medium-temperature stamping correction) of the hot stamping formed part of the composite metal plate exceeds 70 percent. The forming processing efficiency and precision of the material are greatly improved. Only part of formed parts can not meet the requirement after being stamped once, and the shapes of the formed parts need to be corrected by medium-temperature stamping correction, mainly because of the fluctuation of the material performance of the composite metal plate and uncertain factors in the water spray cooling process.
In addition, the performance test can be carried out on metal plates made of different materials, and a material database is perfected. The more complete the types of materials in the database, the more different materials and thicknesses of the composite metal plate can be processed by hot stamping.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (6)
1. A hot stamping forming control method of a composite metal plate is characterized by comprising the following steps:
(1) establishing a finite element model of the existing hot stamping die according to the existing hot stamping die, establishing a finite element model of the composite metal plate according to the raw material size of an actual formed part manufactured by the existing hot stamping die, dividing a grid of the finite element model of the composite metal plate, inputting material performance parameters of each material of the composite metal plate obtained in advance into the finite element model of the composite metal plate, simulating the hot stamping forming and cooling processes of the composite metal plate by using the finite element model of the existing hot stamping die and the finite element model of the composite metal plate input with the material performance parameters, simulating a cooled first simulated formed part size according to the total strain obtained by the material performance parameters, and comparing the first simulated formed part size with the actual formed part size, under the condition that the error is smaller than or equal to a first threshold value, the finite element model of the composite metal plate meets the requirement, under the condition that the error exceeds the first threshold value, the grid of the finite element model of the composite metal plate is refined, and the simulation is carried out again until the error is smaller than or equal to the first threshold value;
(2) establishing a finite element model of a new hot stamping die according to the design size of a formed part to be processed, simulating the hot stamping forming and cooling process of the composite metal plate by combining the finite element model of the composite metal plate meeting the requirement, simulating to obtain the size of a second simulated formed part after cooling, comparing the size of the second simulated formed part with the design size, wherein the finite element model of the new hot stamping die meets the requirement under the condition that the error is less than or equal to a second threshold value, modifying the finite element model of the new hot stamping die under the condition that the error exceeds the second threshold value, and simulating again until the error is less than or equal to the second threshold value;
(3) and casting a solid die by using the finite element model of the new hot stamping die meeting the requirements, and carrying out hot stamping on the composite metal plate by using the solid die.
2. The method of controlling hot press forming of a composite metal plate according to claim 1,
the material performance parameters of each material of the composite metal plate comprise tensile strength, elastic modulus, heat conductivity coefficient, specific heat capacity and linear expansion coefficient of each laminate at different temperatures corresponding to the material of each laminate.
3. The method of controlling hot press forming of a composite metal plate according to claim 1,
the total strain is calculated according to the following formula:
wherein the content of the first and second substances,
is the total strain;
is thermally strained；
Is an elastic strain;
is plastic strain;
is a phase change strain;
the method is phase change shaping.
4. The method of controlling hot press forming of a composite metal plate according to claim 1,
the first threshold is 1%.
5. The method of controlling hot press forming of a composite metal plate according to claim 1,
the second threshold is 1%.
6. The method of controlling hot press forming of a composite metal plate according to claim 1,
the composite metal plate is a metal plate comprising two layers of different metal materials,
and when the finite element model of the composite metal plate is established, the contact surfaces between the two layers of metal plates made of different metal materials are set to be in a combined state.
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| CN106734465A (en) * | 2016-12-12 | 2017-05-31 | 宁波大学 | Based on the hot press-formed method for making automobile B-column of multilayer common metal composite plate |
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| CN101288890A (en) * | 2007-04-18 | 2008-10-22 | 同济大学 | Cooling system of ultra-high strength steel hot stamping forming die |
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