CN108228925A - A kind of method for numerical simulation of complex shapes extrusion process - Google Patents
A kind of method for numerical simulation of complex shapes extrusion process Download PDFInfo
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- CN108228925A CN108228925A CN201611152842.4A CN201611152842A CN108228925A CN 108228925 A CN108228925 A CN 108228925A CN 201611152842 A CN201611152842 A CN 201611152842A CN 108228925 A CN108228925 A CN 108228925A
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- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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- G06—COMPUTING; CALCULATING OR COUNTING
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- G06F30/17—Mechanical parametric or variational design
Abstract
The present invention relates to a kind of method for numerical simulation of complex shapes extrusion process, belong to extruding metal processing technique field.It comprises the steps of：(1) 3-D geometric model of mold and blank is established using CAD software, is input to simulation system；(2) in the shunting stage of profile extrusion, numerical simulation is carried out using finite element fraction one step process；(3) in the soldering of profile extrusion and shaping stage, numerical simulation is carried out using the finite volume method based on Euler (Euler) grid；(4) if section bar flows completely out work band, extrusion process reaches stable state, and entire simulation process terminates, otherwise repeatedly step (3), until reaching stable state.The method for numerical simulation of the complex shapes extrusion process of the present invention has the advantages that the calculating time is short, simulation precision is high, is a kind of largely effective method for carrying out large-size complex-cross-section profile extrusion process study.
Description
Technical field
The present invention relates to a kind of method for numerical simulation of complex shapes extrusion process, more particularly, to a kind of big cross section complexity
The method for numerical simulation of section section bar bridge die extrusion process, belongs to extruding metal processing technique field.
Background technology
Big cross section complex section section bar manufacturing technology represents the highest level of current light-alloy shape extrusion technology.With
Bullet train, city underground and aerospace, naval vessel weapons, machine building industry fast development, to large-size complex-cross-section
The demand of light-alloy section bar increases rapidly, and the enlargement of section bar and the integration of structure can bring huge economy and society
Benefit.
Mold design and manufacturing technology are the key technologies of big cross section complex section aluminium section bar production and restrict its production
One of bottleneck.The characteristics of flat widthization of thin-walled possessed by heavy section, size high precision int, section configuration complicate, to mould
Tool design and manufacture bring very big difficulty.Dependence experience and the traditional moulds of " trial and error " design pattern have been unable to meet modernization
The demand of industry development, introducing the numerical simulation technology progress Extrusion Die Design analysis using computer as tool has become current
The emphasis of research.
But due to metal flow and the complexity of deformation during section bar bridge die extrusion, using traditional based on drawing
There are two problems during the FInite Element progress numerical simulation of Ge Lang grids description：When, it is difficult to accurate simulation hollow profile
Soldering process；Second is that since mesh distortion is particularly acute, need frequently to carry out grid to draw again, cause computational accuracy loss tight
Again or even simulation is terminated, can not continue to calculate.
Therefore, simple shape, sectional dimension are limited only to for the Non-Steady Numerical Simulation of bridge die extrusion process at present
Smaller and small extrusion ratio hollow profile is based on the numerical simulation generally use of big cross section complex section profile extrusion process
The method for numerical simulation of arbitrary order accurasy (Arbitrary Lagrange-Euler, ALE), still, ALE methods are current
Also it is difficult to track the Free Surface of fluid, so as to be difficult to truly simulate the unstable state flowing of metal in section bar extrusion process.Cause
This, ALE methods are substantially carried out the numerical simulation of aluminium section bar stable state extrusion process at present, can not simulate its flowing in mould inside and become
Shape transient.
Existing finite element method has been unable to meet the numerical simulation of the Unsteady Extrusion Processes process of large-size complex-cross-section section bar,
It must seek new simulation method to solve the above problems.
Invention content
The purpose of the present invention is to provide a kind of numerical simulation sides of big cross section complex section section bar bridge die extrusion process
Method solves grid frequently division and the soldering again that conventional finite element method simulation large-size complex-cross-section profile extrusion process can not avoid
The problem that face contacts certainly.
The above-mentioned purpose of the present invention reaches by the following technical programs：
A kind of method for numerical simulation of complex shapes extrusion process, comprises the steps of：
(1) 3-D geometric model of mold and blank is established using CAD software, is input to simulation system；According to current change
Shape condition applies boundary condition, and input material parameter, technological parameter and simulation control parameter；
(2) in the shunting stage of profile extrusion, numerical simulation is carried out using finite element fraction one step process, simulation model is divided
Initial finite element grid sets initial calculation step-length, and establishes simulation and stop decision criteria, re-starts size of mesh opening and calculating
The reset of step-length completes the simulation in shunting stage and exports corresponding numerical simulation result；
(3) it in the soldering of profile extrusion and shaping stage, is carried out using the finite volume method based on Euler (Euler) grid
Numerical simulation, and establish simulation and stop decision criteria, on the basis of the numerical simulation result exported on last stage, complete model
The model needed for limited bulk simulation is established in the transmission of geometric data and various physical field quantity data；
(4) if section bar flows completely out work band, extrusion process reaches stable state, and entire simulation process terminates, otherwise repeats
Step (3), until reaching stable state.
Preferably, the complex shapes refer to section bar circumscribed circle size >=500mm, minimum wall thickness (MINI W.)≤2.5mm, width-thickness ratio >=
220。
Usual this kind of section bar belongs to big cross section complex section class section bar, has larger extrusion ratio, in finite element modelling
Mesh distortion and its acutely in journey, in order to ensure simulation precision, it is necessary to divide closeer unit grid and set smaller calculating
Step-length, but this can a large amount of consumption calculations resources, simulated time is significantly increased.
To solve the above problems, proposing finite element substep analogy method, flow chart is as shown in Figure 1.
Preferably, in the step (2), in the finite element fraction one step process, initial finite element grid is equal sized
Tetrahedral grid, grid cell size z and extruded bars diameter D meet following relationship：Z=(1/15~1/20) * D, it is described
Initial calculation step-length t and pressure ram movement speed v meets following relationship：T=(1/3~1/5) v.
Preferably, in the step (2), the simulation stop technology criterion that is set in finite element multi-stage simulation is：
When the calculating step number that finite element modelling need to repartition due to mesh distortion grid is less than 5 twice in succession, simulation calculates eventually
Only, the division of grid and the setting of step-length are manually re-started.
Preferably, in the step (2), the mesh generation and the principle of material calculation setting of re-starting is：Grid
Unit size z and section bar wall thickness d meets following relationship：Z=(1/2~1/4) * d, material calculation t and pressure ram movement speed v and
Profile extrusion meets following relationship than λ：T=(1/5~1/10) v* λ.
Preferably, it in the step (3), when soldering contacts the metal after shunting again in bonding container, is converted into
Finite volume method, which continues, completes the simulation of bridge die extrusion process, and finite element and limited bulk analogue data transmission method are：If i
For the center lattice point of limited bulk grid system, its local coordinate in finite element grid system is (x, y, z), then i points
Physical field quantity is obtained by following formula (1) interpolation：
In formula, fiAny one physical field quantity (such as stress field, strain that (x, y, z) is limited bulk grid element center lattice point i
Field, velocity field, temperature field etc.), fjFor the corresponding physical field quantity of node each in the finite elements where i points；M is the node of unit
Number, Nj(x, y, z) is the shape function of finite elements, i.e. interpolating function；For the limited body not in finite element grid system
Product center lattice point, by its physical field quantity zero setting；In this way, it just obtains measuring for the initial physical field of limited bulk numerical simulation.
Preferably, in the step (4), the criterion whether profile extrusion enters stable state compression stage is：Using
The flow velocity variance yields S.D. of section bar outlet same position different time node is as judgment basis, as shown in following formula (2)：
In formula, quantity and n >=10, v of the n for taken timing nodeiFor the flow velocity of i-th of timing node, v is institute's having time
The mean flow rate of node as S.D.≤0.1, shows that section bar exit velocity reaches stable state, profile extrusion enters stable state and squeezes rank
Section, at this moment can be automatically stopped simulation.
The advantage of the invention is that：
The method for numerical simulation of the complex shapes extrusion process of the present invention deforms special according to profile extrusion process metal flow
Point is simulated before metal soldering using finite element fraction footwork, the soldering of metal, forming process using finite volume method into
Row simulation, makes full use of two kinds of respective advantages of analogy method, solves conventional finite element method simulation large-size complex-cross-section section bar
The problem that the grid that extrusion process can not avoid frequently divides again and soldering face contacts certainly, under the premise of simulation precision is ensured,
The occupancy of simulation trial time and resource for computer system is greatly reduced, so as to ensure that simulation process can be quickly and smoothly complete
Into.
Below by the drawings and specific embodiments, the present invention will be further described, but is not meant to protect the present invention
Protect the limitation of range.
Description of the drawings
Flow charts of the Fig. 1 for finite element fraction one step process in the method for numerical simulation of complex shapes extrusion process of the present invention.
Fig. 2 is the medium-and-large-sized flat wide thin wall hollow profile sectional view of the embodiment of the present invention 1.
Specific embodiment
Embodiment 1
A kind of method for numerical simulation of complex shapes extrusion process, complex shapes are the wide thin wall hollow profile of Large Flat,
Section is as shown in Fig. 2, width 557mm, high 60mm, basal area 59.88cm2。
As shown in Figure 1, the stream for finite element fraction one step process in the method for numerical simulation of complex shapes extrusion process of the present invention
Cheng Tu.
A kind of method for numerical simulation of complex shapes extrusion process, its step are as follows：
1st, before being simulated, blank, diffluence combination die tool, thimble are first established respectively using Three-dimensional CAD Software
Three-dimensional entity model, the thimble in extrusion system are to apply the component that blank generates movement, can be reduced to a cylindrical rigidity
Face can omit the structural element unrelated with analysis such as screw hole in geometrical model.The geometrical model of each part is assembled and is completed
Afterwards, " STL " formatted file that simulation system is identified is converted to, so that it may obtain the geometrical model needed for simulation system.
2nd, entire extrusion process is divided into multiple stages to simulate.It is divided in each step according to the deformation extent of workpiece
It is suitble to the grid of current deformation condition, and sets corresponding material calculation.The extrusion process of diffluence combination die can be divided into shunting,
Soldering and extrusion molding three phases.
3rd, it is simulated in the shunting stage using finite element fraction one step process (FInite Element), the main collection of this stage workpiece deformation
In in tap hole entrance, and deflection is also smaller, at this moment can divide larger-size grid to workpiece, size of mesh opening be
6mm；Since size of mesh opening is larger, material calculation can also set larger to reduce operation time, and material calculation is set as
0.5mm, the movement speed for then setting pressure ram is 3mm/s, and the initial temperature of workpiece is 480 DEG C, and the preheating temperature of mold is
420 DEG C, the pre-processing file needed for generation simulation carries out first stage finite element modelling.
In finite element fraction one step process, initial finite element grid be equal sized tetrahedral grid, grid cell size z with
Extruded bars diameter D meets following relationship：Z=(1/15~1/20) * D, the initial calculation step-length t and pressure ram movement speed
Degree v meets following relationship：T=(1/3~1/5) v.In the present embodiment, extruded bars diameter D=460mm, grid cell size z
=25mm, pressure ram movement speed v=3mm/s, initial calculation step-length t=1mm.
4th, when the metal after shunting arrives at bonding container bottom, the grid of workpiece bottom and the step-length of setting are not just suitable for
Simulation process, grid division, grid serious distortion will frequently be weighed by continuing finite element modelling, and workpiece occurs with die boundary
More serious interference.At this moment simulation process should be terminated, forces to carry out the division again of grid, progress grid divides again when, field amount
The big mesh generation of variable gradient should be fine and close, and amount variable gradient small local grid in field is sparse, and the grid at workpiece bottom position is adopted
The method segmented with Local grid, grid are set as 2mm, increase degree of freedom in the position of gross distortion, to improve simulation precision.
And reduce material calculation to 0.2mm.When metal stream is full of in bonding container, deformation of the workpiece near mould outlet quite swashs
It is strong, the pressure for carrying out grid again is at this moment needed to divide again, more careful grid is divided near mould outlet, size of mesh opening is set
0.3mm is set to, to protect with simulation precision.With the reduction of grid cell size, correspondingly further reduce material calculation extremely
0.01mm。
Re-starting the principle of mesh generation and material calculation setting is：Grid cell size z expires with section bar minimum wall thickness (MINI W.) d
It is enough lower relationship：Z=(1/2~1/4) * d, material calculation t and pressure ram movement speed v and profile extrusion ratio λ meets with ShiShimonoseki
System：T=(1/5~1/10) v/ λ.In the present embodiment, the minimum wall thickness (MINI W.) d=2.4mm of section bar, pressure ram movement speed v=3mm/
S, profile extrusion is than λ=25.5, the grid cell size z=0.8mm of reset, the material calculation t=of reset
0.02mm。
One complicated deformation process can be divided into several relatively simple deformed by the method for taking multi-stage simulation
Journey so as to be conducive to the division of grid and the setting of increment step-length, significantly reduces the quantity of grid and grid changes number again, drop
The simulation trial time is greatly reduced on the basis of simulation precision is ensured in the low occupancy to resource for computer system.
5th, it in the soldering of profile extrusion, forming process, is simulated using finite volume method, in composite analogy, first
Ensure that the data between different analogy methods can be transmitted accurately, when the metal in bonding container starts that soldering occurs from contact
When, numerical simulation system is transferred to the limited bulk dummy run phase by finite element modelling.
Finite element and limited bulk analogue data transmission method are：If i is the center lattice point of limited bulk grid system, it
Local coordinate in finite element grid system is (x, y, z), then the physical field quantity of i points is obtained by following formula (1) interpolation：
In formula, fi(x, y, z) be limited bulk grid element center lattice point i a certain physical field quantity (such as stress field, strain field,
Velocity field, temperature field etc.), fjFor the corresponding physical field quantity of node each in the finite elements where i points；M is the node of unit
It counts, the tetrahedral grid divided in the present embodiment, the node number m=4, N of unitj(x, y, z) is the shape letter of finite elements
Number, i.e. interpolating function；For the limited bulk center lattice point not in finite element grid system, by its physical field quantity zero setting；This
Sample has just obtained measuring for the initial physical field of limited bulk numerical simulation.
Shown in table 1, during being limited bulk and finite element (finite element fraction one step process or FInite Element) composite analogy
Operational parameter.From table 1 it follows that in simulation calculating process, total calculating time is about 8 hours, although soldering, forming
The time in stage is very of short duration, but violent due to deforming, and it is longer that simulation calculates the time.The grid of wherein finite element modelling divides again
Number is 14 times, and operation time is 15 minutes 5 hours, and the operation time of limited bulk simulation is 41 minutes 2 hours.In limited body
During product module is intended, to improve computational efficiency, Euler (Euler) size of mesh opening is disposed proximate in section bar wall thickness, while to deformation
The discrete of body surface geometry segments technology using net region, and section bar wall thickness is set as to the surface mesh of section bar exit portion
Half, other portion faces size of mesh opening are twice of section bar wall thickness, thus significantly reduce deformable body surface mesh from
Quantity is dissipated, under the premise of simulation precision is ensured, improves computational efficiency.
The operational parameter of 1 limited bulk of table and finite element composite analogy
(4) if section bar flows completely out work band, extrusion process reaches stable state, and entire simulation process terminates, otherwise repeats
Step (3), until reaching stable state.
In step (4), the criterion whether profile extrusion enters stable state compression stage is：It is exported using section bar same
The flow velocity variance yields S.D. of position different time node is as judgment basis, as shown in following formula (2)：
In formula, quantity and n >=10, v of the n for taken timing nodeiFor the flow velocity of i-th of timing node, v is institute's having time
The mean flow rate of node as S.D.≤0.1, shows that section bar exit velocity reaches stable state, profile extrusion enters stable state and squeezes rank
Section, at this moment can be automatically stopped simulation.12 timing nodes of selection in the present embodiment, n=15, when last time is simulated, respectively
The mean flow rate of a node is respectively：86.2、86.3、86.2、86.1、86.2、86.3、86.2、86.2、86、86.1、86.3、
86.2 (unit：Mm/s), by calculating S.D.=0.086, it at this moment can be determined that extruding has been introduced into stable state compression stage, mould
Plan process terminates.
The present invention proposes the limited bulk shaped suitable for large-size complex-cross-section profile extrusion and finite element composite analogy
It in method, i.e. complexity extrusion process, is simulated before metal soldering using FInite Element, soldering, the forming of metal
Process is simulated using finite volume method, makes full use of two kinds of respective advantages of analogy method.In the finite element of soldering forming
A complicated large deformation process is divided into several relatively simple deformation process substeps in simulation process to simulate, is solved
The grid that Finite Element Method Simulation METHOD FOR LARGE DEFORMATION ELASTOPLASTIC process can not avoid frequently divides again causes volume and the problem of loss of significance.It is logical
The interpolation technique for crossing grid node realizes the accurate biography of various physical field quantity data between finite element and limited bulk simulation system
It passs.The method of the present invention has the advantages that the calculating time is short, simulation precision is high, is to carry out large-size complex-cross-section profile extrusion process to grind
A kind of largely effective method studied carefully.
Claims (8)
1. a kind of method for numerical simulation of complex shapes extrusion process, comprises the steps of：
(1) 3-D geometric model of mold and blank is established using CAD software, is input to simulation system；According to current modified strip
Part applies boundary condition, and input material parameter, technological parameter and simulation control parameter；
(2) in the shunting stage of profile extrusion, numerical simulation is carried out using finite element fraction one step process, simulation model is divided initial
Finite element grid sets initial calculation step-length, and establishes simulation and stop decision criteria, re-starts size of mesh opening and material calculation
Reset, complete the shunting stage simulation simultaneously export corresponding numerical simulation result；
(3) in the soldering of profile extrusion and shaping stage, numerical value is carried out using the finite volume method based on Euler (Euler) grid
Simulation, and establish simulation and stop decision criteria, on the basis of the numerical simulation result exported on last stage, complete model geometric
The model needed for limited bulk simulation is established in the transmission of data and various physical field quantity data；
(4) if section bar flows completely out work band, extrusion process reaches stable state, and entire simulation process terminates, otherwise repeatedly step
(3), until reaching stable state.
2. the method for numerical simulation of complex shapes extrusion process according to claim 1, it is characterised in that：The step
(2) in, in the finite element fraction one step process, the initial finite element grid be equal sized tetrahedral grid, grid list
Elemental size z and extruded bars diameter D meets following relationship：Z=(1/15~1/20) * D, the initial calculation step-length t are with squeezing
Compression bar movement speed v meets following relationship：T=(1/3~1/5) v.
3. the method for numerical simulation of complex shapes extrusion process according to claim 2, it is characterised in that：The step
(2) in, the simulation, which stops decision criteria, is：When the calculating step number continuous two that grid need to be repartitioned due to mesh distortion
Secondary when being less than 5, simulation, which calculates, to be terminated, and re-starts the division of grid and the setting of material calculation.
4. the method for numerical simulation of complex shapes extrusion process according to claim 3, it is characterised in that：The step
(2) in, the mesh generation and the principle of material calculation setting of re-starting is：Grid cell size z and section bar wall thickness d meets
Following relationship：Z=(1/2~1/4) * d, material calculation t and pressure ram movement speed v and profile extrusion ratio λ meet following relationship：
T=(1/5~1/10) v* λ.
5. the method for numerical simulation of complex shapes extrusion process according to claim 4, it is characterised in that：The step
(3) it in, when soldering contacts the metal after shunting again in bonding container, is converted into finite volume method and continues and complete divergent die
The simulation of extrusion process, finite element and limited bulk analogue data transmission method are：If i is the center of limited bulk grid system
Lattice point, its local coordinate in finite element grid system are (x, y, z), then the physical field quantity of i points is obtained by following formula (1) interpolation
It arrives：
In formula, fiAny one physical field quantity of (x, y, z) for limited bulk grid element center lattice point i, fjIt is limited where i points
Each corresponding physical field quantity of node in unit；Node numbers of the m for unit, Nj(x, y, z) is the shape function of finite elements, that is, is inserted
Value function for the limited bulk center lattice point not in finite element grid system, its physical field quantity zero setting obtains having
Limit the initial physical field amount of volumetric quantities simulation.
6. the method for numerical simulation of complex shapes extrusion process according to claim 5, it is characterised in that：It is described any one
A physical field quantity is stress field, strain field, velocity field or temperature field.
7. the method for numerical simulation of complex shapes extrusion process according to claim 6, it is characterised in that：The step
(4) in, the criterion whether profile extrusion enters stable state compression stage is：Same position different time is exported using section bar
The flow velocity variance yields S.D. of node is as judgment basis, as shown in following formula (2)：
In formula, quantity and n >=10, v of the n for taken timing nodeiFor the flow velocity of i-th of timing node,For institute's having time section
The mean flow rate of point；As S.D.≤0.1, show that section bar exit velocity reaches stable state, profile extrusion enters stable state compression stage.
8. the method for numerical simulation of complex shapes extrusion process according to claim 1, it is characterised in that：The complexity
Material refers to section bar circumscribed circle size >=500mm, minimum wall thickness (MINI W.)≤2.5mm, width-thickness ratio >=220.
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| CN110686610A (en) * | 2019-09-11 | 2020-01-14 | 北京大学 | Optical deformation measuring method based on self-adaptive grid and electronic equipment |
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| CN109086489A (en) * | 2018-07-03 | 2018-12-25 | 广东工业大学 | A kind of the energy consumption modeling and analysis method of diffluence combination die extrusion molding |
| CN109033554A (en) * | 2018-07-04 | 2018-12-18 | 北京航空航天大学 | A kind of turbine disk cold holes expansion technique Numerical Simulation analogy method |
| CN109967545A (en) * | 2019-04-03 | 2019-07-05 | 山东科技大学 | Cross weld and discard method for determining dimension in aluminum profile production process |
| CN110686610A (en) * | 2019-09-11 | 2020-01-14 | 北京大学 | Optical deformation measuring method based on self-adaptive grid and electronic equipment |
| CN110686610B (en) * | 2019-09-11 | 2020-12-22 | 北京大学 | Optical deformation measuring method based on self-adaptive grid and electronic equipment |
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| CN112364533A (en) * | 2020-07-22 | 2021-02-12 | 国网江西省电力有限公司电力科学研究院 | Forging forming simulation analysis method of aluminum alloy material hardware fitting for power transmission line |
| CN113094951A (en) * | 2021-04-02 | 2021-07-09 | 中北大学 | Design method of step-by-step extrusion die capable of effectively reducing box forming load |
| CN113094951B (en) * | 2021-04-02 | 2022-10-25 | 中北大学 | Design method of step-by-step extrusion die capable of effectively reducing forming load of box body |
| CN117521430A (en) * | 2024-01-08 | 2024-02-06 | 武汉理工大学 | Rapid optimization method for flow dividing holes of hollow profile extrusion die |
| CN117521430B (en) * | 2024-01-08 | 2024-03-26 | 武汉理工大学 | Rapid optimization method for flow dividing holes of hollow profile extrusion die |
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