CN110732580A - Method for establishing general rotation flange wrinkling prediction model - Google Patents

Method for establishing general rotation flange wrinkling prediction model Download PDF

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CN110732580A
CN110732580A CN201910937991.9A CN201910937991A CN110732580A CN 110732580 A CN110732580 A CN 110732580A CN 201910937991 A CN201910937991 A CN 201910937991A CN 110732580 A CN110732580 A CN 110732580A
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flange
wrinkling
establishing
compressive stress
critical
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CN110732580B (en
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詹梅
高鹏飞
陈淑婉
马飞
张洪瑞
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Northwestern Polytechnical University
Northwest University of Technology
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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
    • B21D22/14—Spinning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F

Abstract

The invention discloses a method for establishing a general rotation flange wrinkling prediction model, which is based on a plastic forming theory and general rotation mechanics characteristics, and establishes a flange maximum circumferential compressive stress model; based on a limit theory, establishing a flange critical circumferential compressive stress model by combining the characteristics of flange corrugation in the common spin; establishing a stable mechanical condition of the flange in the normal rotation process; establishing a relation between common rotation parameters in a critical wrinkling state; the invention comprehensively considers the circumferential shrinkage of the flange in the common rotation process and the circumferential bending under the action of the spinning wheel force to establish a flange wrinkle prediction model in the common rotation, and can truly reflect the forming characteristics of the flange in the actual production. According to the method, the maximum circumferential compressive stress model and the critical circumferential compressive stress model of the flange are established by a theoretical calculation method, the slab general rotation test and finite element simulation which are complicated in process and time-consuming and consumable are avoided, the wrinkling prediction result is free from the influence of a finite element modeling form and calculation precision, and the flange wrinkling defect in the general rotation is accurately and quickly predicted.

Description

Method for establishing general rotation flange wrinkling prediction model
Technical Field
The invention relates to the field of sheet forming processing, in particular to a method for establishing and using a flange wrinkling prediction model in a common spin, which is mainly used for judging unstable wrinkling of a flange in the common spin, evaluating the forming performance of the flange, acquiring a formable domain of a plate blank and providing theoretical guidance for the design of forming parameters and a spinning wheel path in the common spin.
Background
The spinning of the metal sheet is local plastic deformation processes, the local plastic deformation of the plate blank clamped by the tail top and the mandrel is generated by the force of a spinning wheel, the local plastic deformation gradually expands to the whole plate blank along with the high-speed rotation of the mandrel and the feeding motion of the spinning wheel, the spinning process of the metal sheet plays an important role in the manufacturing of aviation, aerospace and civil products due to the unique advantages of small forming force, high forming performance and the like.
At present, three methods for predicting the general spinning wrinkling are provided, namely a geometric visual method, a spinning pressure method and a theoretical analytical method, wherein the geometric visual method represents the fluctuation condition of the flange through the average value and the standard deviation of the axial fluctuation of the outer edge of the spinning flange, and the spinning pressure method judges the wrinkling moment according to the spinning pressure oscillation amplitude.
Disclosure of Invention
Aiming at the limitations of the conventional common-spin flange wrinkling prediction method, the invention provides an establishment and use method of common-spin flange wrinkling prediction models, which is used for rapidly and accurately judging the wrinkling defects of the common-spin flange and effectively evaluating the forming performance of a plate blank.
The invention is realized by adopting the following technical scheme: the method for establishing the pre-rotation flange wrinkling prediction model is realized by the following steps,
s1, establishing a maximum circumferential compressive stress model of a flange based on a plastic forming theory and a general rotation mechanics characteristic:
Figure BDA0002222103530000021
wherein K is the material strain strengthening coefficient, n is the material hardening index, sigmaθmaxIs the maximum circumferential compressive stress of the flange, epsilonθmaxFor maximum circumferential compressive strain at the flange outer edge during pronation, when the spinning wheel path is straight lines, εθmaxThe analytical solution of (a) is expressed as:
Figure BDA0002222103530000022
wherein R is0Is the radius of the core mold, b0Is the initial radius of the slab, f is the feed ratio of the rotary wheel, α is the linear rotationThe wheel path half cone angle, n' is the mandrel parameter.
S2, based on a limit theory and in combination with the characteristics of the flange wrinkle wave in the normal spin, establishing a flange critical circumferential compressive stress model:
Figure BDA0002222103530000023
wherein σsMaterial yield stress, t slab thickness, α0Is the instantaneous half-cone angle of the spinning wheel path.
S3, establishing a stable mechanical condition of the flange in the normal rotation process:
σθmax≤σθcr(4)
s4, establishing a relation between the ordinary rotation parameters under a critical wrinkling state:
Figure BDA0002222103530000024
wherein epsilonθcrWhen the rotor path is straight line, εθcrThe analytic solution of (d) can be expressed as:
wherein, n'crIs the mandrel parameter in the critical wrinkling state.
The use method of the established propulsive model for the flange wrinkling in the pronation comprises the following steps:
1) respectively substituting the given plate blank material parameters, the given geometric parameters and the given ordinary rotation process parameters into a flange maximum circumferential compressive stress model (formula (1)) and a critical circumferential compressive stress model (formula (3)), comparing the obtained flange maximum circumferential compressive stress with the critical circumferential compressive stress, and if the flange maximum circumferential compressive stress reaches or is greater than the critical value, considering that the flange in the ordinary rotation is unstable and wrinkled; if the maximum circumferential compressive stress of the flange is less than its critical value, the slab is considered to be successfully formed in the normal spin.
2) And (4) calculating the wrinkling moment of the plate blank or the limit parameter value of successful forming according to the relation (formula (5)) between the ordinary rotation parameters under the critical wrinkling state.
When the forming machine is used, the limit half cone angles of the slabs of series with different steel grades and different geometric dimensions, which can be successfully formed, are compared, the forming performance of the slab with the minimum limit half cone angle is the best, and the forming performance of the slab with the maximum limit half cone angle is the worst.
The method is suitable for general spinning forming with various types of spinning wheel paths.
Compared with the prior art, the invention has the following advantages:
1) the invention comprehensively considers the circumferential shrinkage of the flange in the common rotation process and the circumferential bending under the action of the spinning wheel force to establish a flange wrinkle prediction model in the common rotation, and can truly reflect the forming characteristics of the flange in the actual production.
2) According to the method, the maximum circumferential compressive stress model and the critical circumferential compressive stress model of the flange are established by a theoretical calculation method, the slab general rotation test and finite element simulation which are complicated in process and time-consuming and consumable are avoided, the wrinkling prediction result is free from the influence of a finite element modeling form and calculation precision, and the flange wrinkling defect in the general rotation is accurately and quickly predicted.
Drawings
FIG. 1 is a generalized spin forming diagram of a 1mm thick slab under a straight spinning wheel path, with consideration of wrinkling defects.
FIG. 2 is a sample of a 1060 aluminum alloy pronation test of a 1mm thick slab: (a) a half cone angle of 60 DEG and (b) a half cone angle of 70 deg.
Fig. 3 is a linear spinning wheel path limiting half cone angle for different material hardening indices.
Detailed Description
The model for predicting the wrinkle of the convex edge in the normal spin established by the invention can be used for successfully predicting the wrinkle defect of the convex edge in the normal spin, effectively evaluating the forming performance of the model and reasonably guiding the design of the normal spin process.
The method for establishing the pre-rotation flange wrinkling prediction model is realized by the following steps,
s1, establishing a maximum circumferential compressive stress model of a flange based on a plastic forming theory and a general rotation mechanics characteristic:
Figure BDA0002222103530000031
wherein K is the material strain strengthening coefficient, n is the material hardening index, sigmaθmaxIs the maximum circumferential compressive stress of the flange, epsilonθmaxFor maximum circumferential compressive strain at the flange outer edge during pronation, when the spinning wheel path is straight lines, εθmaxThe analytical solution of (a) is expressed as:
Figure BDA0002222103530000032
wherein R is0Is the radius of the core mold, b0The initial slab radius, f the feed ratio of the wheel, α the half cone angle of the linear wheel path, and n' the mandrel parameters.
S2, based on a limit theory and in combination with the characteristics of the flange wrinkle wave in the normal spin, establishing a flange critical circumferential compressive stress model:
Figure BDA0002222103530000033
wherein σsMaterial yield stress, t slab thickness, α0Is the instantaneous half-cone angle of the spinning wheel path.
S3, establishing a stable mechanical condition of the flange in the normal rotation process:
σθmax≤σθcr(4)
s4, establishing a relation between the ordinary rotation parameters under a critical wrinkling state:
Figure BDA0002222103530000034
wherein epsilonθcrWhen the rotor path is straight line, εθcrThe analytic solution of (d) can be expressed as:
Figure BDA0002222103530000041
wherein, n'crIs the mandrel parameter in the critical wrinkling state.
The use method of the established propulsive model for the flange wrinkling in the pronation comprises the following steps:
1) respectively substituting the given plate blank material parameters, the given geometric parameters and the given ordinary rotation process parameters into a flange maximum circumferential compressive stress model (formula (1)) and a critical circumferential compressive stress model (formula (3)), comparing the obtained flange maximum circumferential compressive stress with the critical circumferential compressive stress, and if the flange maximum circumferential compressive stress reaches or is greater than the critical value, considering that the flange in the ordinary rotation is unstable and wrinkled; if the maximum circumferential compressive stress of the flange is less than its critical value, the slab is considered to be successfully formed in the normal spin.
2) And (4) calculating the wrinkling moment of the plate blank or the limit parameter value of successful forming according to the relation (formula (5)) between the ordinary rotation parameters under the critical wrinkling state.
When the forming machine is used, the limit half cone angles of the slabs of series with different steel grades and different geometric dimensions, which can be successfully formed, are compared, the forming performance of the slab with the minimum limit half cone angle is the best, and the forming performance of the slab with the maximum limit half cone angle is the worst.
The method is suitable for general spinning forming with various types of spinning wheel paths.
EXAMPLE this example is a method of using Prolate middle ridge wrinkle prediction models in this example, the material strain hardening exponent K of the slab is 93.9396MPa, the hardening coefficient n is 0.1792, and the outer diameter b of the slab is0Is 78mm, core radius R0At 45mm, the initial wall thickness t was 1mm, the feed ratio f was 0.4mm/r, and the linear impeller path half cone angle α was 60 deg. based on equations (5) and (6), the corrugation time was 10.7 s.
In the second embodiment, the present embodiment is a method for using an normal rotation flange wrinkling prediction model, in which fig. 1 shows a forming diagram of a 1mm thick plate blank considering wrinkling defects under a straight-line spinning wheel path established based on the normal rotation flange wrinkling prediction model, in which a curved surface is a wrinkling critical surface, an upper side thereof is a safe forming area, and a lower side thereof is a wrinkling area, given values of forming parameters, positions of corresponding points in the forming diagram can be determined, and if the corresponding points are located below the wrinkling critical surface, it means that wrinkling defects occur in the flange during normal rotation, fig. 2 shows a normal rotation experimental sample of an aluminum alloy of the 1mm thick plate blank 1060, when f is 0.3mm/r and α ° 60 °, corresponding points in the forming diagram are located in the wrinkling area, a small amount of flange occurs, and the normal piece cannot be successfully formed under existing process conditions (fig. 2(a)), in order to ensure forming quality of the rotating piece, the forming parameters can be adjusted according to the forming diagram considering the defects, f is 0.3mm/r, and the flange is located in the safe forming diagram (362) (α ° is successfully formed).
Third example this example is the method of using types of prediction models for the formation of proud ridges in the normal spin fig. 3 shows the limit half-cone angles of the path of a straight spinning wheel that can be successfully formed at different material hardening indexes n based on equation (5).
The method for establishing and using the common spin flange wrinkling prediction model can accurately establish a forming diagram considering wrinkling defects, successfully predict wrinkling defects of the common spin flange, effectively evaluate the forming performance of the common spin flange, and reasonably guide the design of a common spin process.

Claims (7)

1. The method for establishing the general rotation flange wrinkling prediction model is characterized by comprising the following steps of:
s1, establishing a maximum circumferential compressive stress model of a flange based on a plastic forming theory and a general rotation mechanics characteristic;
s2, establishing a flange critical circumferential compressive stress model based on a limit theory and combined with the characteristics of flange corrugation in the normal spin;
s3, establishing a stable mechanical condition of the flange in the normal rotation process;
and S4, establishing a relation between the ordinary rotation parameters in a critical wrinkling state.
2. A method of developing a prophy flange corrugation prediction model according to claim 1, wherein:
establishing a maximum circumferential compressive stress model of the flange based on a plastic forming theory and a common rotation mechanics characteristic:
Figure FDA0002222103520000011
wherein K is the material strain strengthening coefficient, n is the material hardening index, sigmaθmaxIs the maximum circumferential compressive stress of the flange, epsilonθmaxIs the maximum circumferential compressive strain at the flange outer edge in the normal rotation process, and when the rotating wheel path is straight lines, epsilonθmaxThe analytical solution of (a) is expressed as:
Figure FDA0002222103520000012
wherein R is0Is the radius of the core mold, b0The initial slab radius, f the feed ratio of the wheel, α the half cone angle of the linear wheel path, and n' the mandrel parameters.
3. A method of developing a prophy flange corrugation prediction model according to claim 2, wherein:
based on a limit theory, combining with the characteristics of the flange wrinkle wave in the ordinary spin, establishing a flange critical circumferential compressive stress model:
wherein σSMaterial yield stress, t slab thickness, α0Is the instantaneous half-cone angle of the spinning wheel path.
4. A method of developing a prophy flange corrugation prediction model according to claim 3, wherein: establishing a mechanical condition for stabilizing the flange in the normal rotation process:
σθmax≤σθcr(4)。
5. a method of developing a prophy flange wrinkling prediction model according to claim 4, wherein: establishing a relation between common rotation parameters under a critical wrinkling state:
Figure FDA0002222103520000014
wherein epsilonθcrCritical buckling condition, circumferential compressive strain at the outer edge of the flange, and when the spinning wheel path is straight line,. epsilonθcrThe analytical solution of (a) is expressed as:
Figure FDA0002222103520000015
wherein, n'crIs the mandrel parameter in the critical wrinkling state.
6. A method of developing a prophy flange wrinkling prediction model according to claim 5, wherein: the use method of the established propulsive model for the flange wrinkling in the pronation comprises the following steps:
1) respectively substituting given plate blank material parameters, geometric parameters and normal rotation process parameters into a flange maximum circumferential compressive stress model formula (1) and a critical circumferential compressive stress model formula (3), comparing the obtained flange maximum circumferential compressive stress with the critical circumferential compressive stress, and if the flange maximum circumferential compressive stress reaches or is greater than the critical value, considering that unstable wrinkling occurs to the flange in the normal rotation; if the maximum circumferential compressive stress of the flange is smaller than the critical value, the common-rotation middle plate blank is considered to be successfully formed;
2) and calculating the wrinkling moment of the plate blank or the limit parameter value capable of being successfully formed according to the relation (5) between the ordinary rotation parameters in the critical wrinkling state.
7. A method for establishing a predictive model of purl flange wrinkling according to claim 6 wherein, in use, the minimum half cone angle of the slabs with the minimum half cone angle is most formed and the maximum half cone angle of the slabs with the maximum half cone angle is least formed by comparing the maximum half cone angles of the slabs with different steel grades and different geometric dimensions of series.
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CN103831336A (en) * 2014-03-25 2014-06-04 揭阳市兴财金属制品有限公司 Vertical type multi-wheel spinning lathe for thinning thin-cylinder workpiece through rolling machining
CN104550393A (en) * 2014-12-03 2015-04-29 华南理工大学 Method for precision forming of concave-bottom and thin-wall cylindrical part with large length and diameter ratio
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