CN110826280A - Process optimization method for improving cylindrical part drawing lug based on finite element simulation - Google Patents
Process optimization method for improving cylindrical part drawing lug based on finite element simulation Download PDFInfo
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- 238000004088 simulation Methods 0.000 title claims abstract description 39
- 238000005457 optimization Methods 0.000 title claims abstract description 14
- 238000012360 testing method Methods 0.000 claims abstract description 13
- 239000007769 metal material Substances 0.000 claims abstract description 7
- 238000009864 tensile test Methods 0.000 claims abstract description 7
- 238000005096 rolling process Methods 0.000 claims description 3
- 239000012467 final product Substances 0.000 abstract 1
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- 238000004519 manufacturing process Methods 0.000 description 8
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Abstract
The invention provides a process optimization method for improving a cylindrical part drawing lug based on finite element simulation, which comprises the following steps: (1) selecting any metal material with anisotropy, and measuring plastic strain ratio R values of the metal material in a plurality of directions on a tensile testing machine; (2) d, carrying out drawing simulation on the cylindrical piece by using DYNAFORM software, and outputting a lug value of the cylindrical piece according to a simulation result; (3) selecting a plurality of single factors according to actual working conditions; (4) selecting a plurality of numerical values for each single factor by controlling variables, respectively carrying out drawing simulation when the other factors are unchanged, and analyzing the lug value result to obtain the influence weight of different factors; (5) and performing orthogonal test drawing simulation, comparing the final results, and combining the single factors with the minimum lug value to obtain the optimal drawing process. The method can optimize the drawing process, so that the phenomenon of lugs can be effectively relieved when the cylindrical part is drawn, and the qualification rate and the utilization rate of the final product are improved.
Description
Technical Field
The invention belongs to the field of forming of materials, and particularly relates to a process optimization method for improving a cylindrical part drawing lug based on finite element simulation.
Background
Drawing is a processing procedure of deforming a flat metal plate into an open hollow cylindrical part by using the plasticity of the plate and using a special die. The method is one of the most typical forming procedures in the stamping process, and is widely applied to actual stamping production. It is also possible to form parts with more complex shapes if coupled with other stamping processes. The size range of deep drawing processing is quite wide, and the deep drawing processing can be carried out on small parts with the size of several millimeters to large parts with the outline size of 2-3 meters and the thickness of 200-300 millimeters. Therefore, in the industrial sectors of machinery, electrical appliances, instruments and electronics, and the stamping production of daily necessities, most of the covering parts of the automobile body are processed by a drawing process, so that the drawing process is particularly important in the industrial production.
After the blank is drawn, the mouth of the cylindrical member tends to be uneven in height, and this phenomenon is called a lug. Wherein, the higher part of the mouth part is called a lug (ear) and the lower part is called a trough (trough). In order to obtain a flat part edge, a trimming procedure is often needed to be added to cut off the lug, and the more obvious the lug needs to cut off more material, the more serious the waste is; meanwhile, the added trimming die improves the production cost, increases the total production time of parts and influences the working efficiency. Therefore, the research on the die and the process in the drawing process to improve the lug phenomenon has great research significance on reducing the cost and improving the efficiency of the plate stamping forming in industry.
The traditional analysis method is to manufacture a die according to experience and then perform trial punching, and when a part obtained by the trial punching has a defect, the die repair and the trial punching are required to be performed repeatedly until a good result is obtained. The defects of the traditional method are that a great deal of time, labor and financial resources are generally needed, the quality of the designed product is not guaranteed, and more resources are inevitably wasted. Therefore, the finite element simulation has good guiding significance for improving the production quality of the cylindrical part, shortening the period of the stamping process design, reducing the production cost and the like.
Disclosure of Invention
The invention aims to analyze and calculate the cylindrical part by adopting a finite element simulation method, so that the reasonability and the reliability of a drawing process can be better ensured, the research and development period of a die is greatly shortened, and the material utilization rate is improved so as to achieve the aim of saving the cost.
In order to solve the technical problem, the invention provides a process optimization method for improving a barrel drawing lug based on finite element simulation, which mainly comprises the following steps:
(1) selecting any metal material with anisotropy, and measuring plastic strain ratio R values of the metal material in a plurality of directions on a tensile testing machine;
(2) d, carrying out drawing simulation on the cylindrical part by using DYNAFORM software, and outputting a lug value according to a simulation result to be compared with an actual condition so as to ensure that the boundary condition of the drawing simulation is consistent with the actual working condition;
(3) selecting a plurality of single factors according to actual working conditions;
(4) selecting a plurality of numerical values for each single factor by controlling variables, respectively carrying out drawing simulation when the other factors are unchanged, and analyzing the lug value result to obtain the influence weight of different factors;
(5) and performing orthogonal test drawing simulation, comparing the final results, and combining the single factors with the minimum lug value to obtain the optimal drawing process.
Preferably, because the largest factor of influence of the deep-drawing piece lug is the plastic strain ratio R value of the selected material, and in the practical production process, the material is generally not allowed to change due to the limitation of cost and the like, a tensile test is firstly carried out on a tensile testing machine to determine the plastic strain ratio R value of the material in three directions (0 degrees, 45 degrees and 90 degrees relative to the rolling direction).
Preferably, when the DYNAFORM is used for simulating the initial drawing of the cylindrical part, the boundary conditions of the drawing simulation are ensured to be consistent with the actual working conditions, and the lug value obtained by final simulation is compared with the lug value obtained by actual measurement, so that the error is ensured not to exceed 5%, and the accuracy of finite element analysis is ensured.
Preferably, the method of orthogonal testing comprises: selecting single factors in the step (3), selecting 6 single factors of blank holder force, drawing speed, bevel edge angle of a male die, fillet of a female die, clearance of a male die and a female die and friction coefficient according to actual working conditions in the drawing process, respectively selecting 5 horizontal factors, firstly performing a single-factor drawing test, and then performing a 6-factor 5 horizontal orthogonal test.
The invention has the advantages and effects that: the method combines DYNAFORM finite element simulation with the traditional deep drawing method, obtains a process optimization method for improving the deep drawing lug of the cylindrical part through numerical simulation analysis and calculation, improves the product quality of the cylindrical part, improves the product percent of pass and the material utilization rate, and reduces the cost.
Drawings
The invention will be further explained with reference to the drawings
FIG. 1 is a flow chart of a process optimization method of the present invention;
FIG. 2 is a diagram of results of finite element simulations prior to process optimization;
FIG. 3 is a diagram of results of finite element simulations after process optimization.
Detailed Description
Example (b):
as shown in FIG. 1, the invention relates to a process optimization method for improving a barrel drawing lug based on finite element simulation, which comprises the following steps:
1. determination of the plastic strain ratio r value: according to the requirements of GB/T5027-2016 metal material sheet and thin strip plastic strain ratio (R value) of the national standard, 5 dumbbell test pieces are respectively taken on the taken material in the directions of 0 degree, 45 degrees and 90 degrees with the rolling direction by using linear cutting, and then the R value is obtained on a tensile testing machine according to the required operation.
2. And (2) establishing a three-dimensional model of the cylindrical part by utilizing UG three-dimensional modeling software according to a two-dimensional die drawing of the cylindrical part, then introducing the three-dimensional model into finite element analysis software DYNAFORM, dividing the three-dimensional model into grids, inputting the measured plastic strain ratio R value into DYNAFORM, inputting the original working condition according to a process file, then carrying out drawing simulation, comparing the result with the actual result, ensuring that the error is not more than 5%, and ensuring the accuracy of finite element analysis.
3. Single factor numerical simulation: according to theory and actual conditions, various factors which cause the generation of lugs in the part drawing forming process are comprehensively considered, wherein the factors comprise 6 factors of blank holder force, drawing speed, bevel edge angle of a male die, fillet of a female die, clearance between the male die and the female die and friction coefficient.
4. Firstly, 5 horizontal values of a single factor are determined, then, variables are respectively controlled to carry out 5 times value simulation on one factor, a lug value is output according to a simulation result, and the lug value result is analyzed to obtain influence weights of different factors.
5. Orthogonal test: and (3) carrying out scheme design of orthogonal test according to 6-factor 5 level to ensure that the selected orthogonal combinations are uniformly distributed and representative in the test range, then introducing each orthogonal combination into DYNAFORM to carry out finite element analysis simulation one by one, counting the lug values of the orthogonal combinations, and finally determining the optimal process combination of the six factors according to the minimum lug value of the orthogonal combination. As shown in fig. 2, the result of finite element simulation before optimization and fig. 3, the result of finite element simulation after optimization, it is obvious that the process effect of fig. 3 is much better than that of fig. 2.
The method is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention should be covered within the scope of the present invention. Therefore, the technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.
Claims (4)
1. A process optimization method for improving a barrel drawing lug based on finite element simulation is characterized by comprising the following operation steps:
selecting any metal material with anisotropy, and measuring plastic strain ratio R values of the metal material in a plurality of directions on a tensile testing machine;
carrying out drawing simulation on the cylindrical part by using DYNAFORM software, and outputting an initial lug value according to a simulation result to be compared with an actual condition so as to ensure that the boundary condition of the drawing simulation is consistent with the actual working condition;
selecting a plurality of single factors according to actual working conditions;
selecting a plurality of numerical values for each single factor by controlling variables, respectively carrying out drawing simulation when the other factors are unchanged, and analyzing the lug value result to obtain the influence weight of different factors;
and performing orthogonal test drawing simulation, comparing the final results, and combining the single factors with the minimum lug value to obtain the optimal drawing process.
2. The method for optimizing process of improving drawing lug of barrel part based on finite element simulation as claimed in claim 1, wherein in step (1) plastic strain ratio R values in three directions are measured on a tensile testing machine, wherein the three directions are respectively 0 °, 45 ° and 90 ° from the rolling direction.
3. The process optimization method for improving the barrel drawing lug based on finite element simulation as claimed in claim 1, wherein 6 single factors are selected in the step (3), and are blank holder force, drawing speed, bevel angle of a male die, fillet of a female die, clearance between the male die and the female die and friction coefficient.
4. The method for optimizing the process for improving the deep drawing lug of the cylindrical part based on the finite element simulation as claimed in claim 3, wherein the orthogonal test in the step (5) is that 5 horizontal factors are respectively selected for 6 single factors, and the single factor deep drawing test is firstly carried out, and then the 6 factor 5 horizontal orthogonal test is carried out.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112275879A (en) * | 2020-09-30 | 2021-01-29 | 首钢集团有限公司 | Forming die for reducing lug making height of sheet drawing forming and preparation method thereof |
| CN115138740A (en) * | 2022-07-18 | 2022-10-04 | 重庆长安汽车股份有限公司 | Method and system for determining tensile crack depth of automotive stamped steel plate |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104765912A (en) * | 2015-03-25 | 2015-07-08 | 湖南大学 | Robustness optimizing method of aluminum plate punching process |
| CN106096094A (en) * | 2016-05-31 | 2016-11-09 | 北方工业大学 | Method for eliminating anisotropic material cylindrical part drawing lug based on finite element simulation |
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2019
- 2019-11-11 CN CN201911094290.XA patent/CN110826280A/en active Pending
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104765912A (en) * | 2015-03-25 | 2015-07-08 | 湖南大学 | Robustness optimizing method of aluminum plate punching process |
| CN106096094A (en) * | 2016-05-31 | 2016-11-09 | 北方工业大学 | Method for eliminating anisotropic material cylindrical part drawing lug based on finite element simulation |
Non-Patent Citations (1)
| Title |
|---|
| 伍世鹏: "压缩机外壳拉深凸耳的仿真分析与坯料形状优化" * |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112275879A (en) * | 2020-09-30 | 2021-01-29 | 首钢集团有限公司 | Forming die for reducing lug making height of sheet drawing forming and preparation method thereof |
| CN112275879B (en) * | 2020-09-30 | 2022-04-19 | 首钢集团有限公司 | Forming die for reducing lug making height of sheet drawing forming and preparation method thereof |
| CN115138740A (en) * | 2022-07-18 | 2022-10-04 | 重庆长安汽车股份有限公司 | Method and system for determining tensile crack depth of automotive stamped steel plate |
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