CN116429590A - Metal sheet bulging test device and method capable of realizing continuous rotation of stress main shaft - Google Patents
Metal sheet bulging test device and method capable of realizing continuous rotation of stress main shaft Download PDFInfo
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Abstract
The invention belongs to the field of performance test of metal sheets under complex nonlinear loading conditions, and provides a metal sheet bulging test device and method capable of realizing continuous rotation of a stress main shaft. The invention changes the constraint boundary condition of the metal sheet pole in the bulging process by changing the axial length ratio value and the length axial direction of the ellipse of the upper die cross section of the rotary female die, thereby realizing the change of the primary and secondary stress direction and the size in the plane of the metal sheet pole in bulging. By the device and the method, the accurate constitutive model of the metal sheet can be built under the condition of being closer to the actual forming process; the rotating path, the size changing path, the metal sheet material direction and the initial included angle of the stress main shaft direction can be adjusted according to actual requirements.
Description
Technical Field
The invention relates to the field of performance test of metal sheets under complex nonlinear loading conditions, in particular to a metal sheet bulging test device and method capable of realizing continuous rotation of a stress main shaft.
Background
With the great improvement of the requirements of the aerospace and automobile industry on light weight, reliability, long service life and the like, the requirement of adopting an integral special-shaped thin shell component to replace the traditional block splice welding assembly structure is increasingly urgent. To achieve the formation of complex profiled thin-walled monolithic components, it is often necessary to undergo complex deformation processes in which changes in the shape, dimensions and boundary conditions of the blank all result in the loading path exhibiting complex nonlinearities: while the stress path is continuously changing, the stress principal axis direction is continuously and complexly rotated. In addition, due to the directionality of the manufacturing process, the actual sheet material has a degree of anisotropy, so that different material directions can exhibit different deformation characteristics and forming properties when matched to different loading paths. Therefore, in order to realize accurate description and characterization of the deformation characteristics of the plate in the complex forming process, for guiding the actual forming, experiments which are as close as possible to the conditions of blank and die constraint during the actual forming are needed to obtain corresponding data such as stress, strain and the like.
For testing the deformation performance of the thin plate, the currently mainly adopted methods include simple proportional loading, such as a unidirectional stretching/compression method, a circular/elliptic section female die bulging method and the like, and non-proportional loading developed on the basis of the simple proportional loading, such as a bidirectional loading cross stretching method, a stepped female die bulging method (patent number 201611240021.6) and the like. The simple proportional loading method obtains the performance of the thin plate under a certain specific and unchanged plane stress state, and the stress path and the stress main axis direction are unchanged, which is far from the complex loading process of the plate in actual deformation. In non-proportional loading, the two-way loading cross stretching method changes the ratio of two main stresses which are mutually perpendicular in the plane in the deformation process by changing the stretching force and the stretching speed in two mutually perpendicular directions on a cross sample. However, when the equivalent strain exceeds 10% or even less, the sample has deviated from the original shape seriously, the deformation is extremely unstable and uncontrollable, the stress-strain data obtained by the subsequent deformation is seriously distorted and unusable, the stress and strain information of the material in the unstable deformation and final failure and destruction stage in the later stage of the test cannot be obtained, and the deformation behavior measurement of the plate in this stage is crucial for the evaluation of the forming capability and the determination of the forming process.
As an improved novel non-proportional loading method, a step die bulging method (patent No. 201611240021.6) adopts a step die with a cross section shape which is continuously changed along the bulging height direction to perform bulging, so that the stress ratio of a middle deformation zone of a metal plate blank in the whole bulging process is continuously changed, and non-proportional loading deformation is obtained. Due to the continuous stability of the bulging loading process and the visual visibility of CCD camera data acquisition, the method can obtain plate deformation data in a larger equivalent strain range, and stress and strain information of unstable deformation at the later stage of the test and the final failure and destruction stage can also be acquired in real time, so that the method provides possibility for more comprehensively evaluating the performance of the metal sheet. However, the method can only change the stress ratio by changing the ratio of the long shaft to the short shaft of each step female die, can not realize the rotation of the stress main shaft in the plate bulging area, can not obtain the deformation performance of the plate under the condition of continuous rotation of the stress main shaft, can not accurately represent the influence of continuous and complex changes of the material direction and the stress direction on the material forming performance during actual forming, and has limited application prospect.
In addition, the original sheet used for forming the complex profiled thin-walled workpiece generally has an initial anisotropy, and the degree and direction of the anisotropy are changed after undergoing deformation with continuously changing boundary conditions during the forming process. In the prior test method, only the initial included angle between the direction of the material and the direction of the stress main axis before deformation is set, and the included angle between the directions in the subsequent deformation cannot be actively and accurately controlled, which is greatly different from the deformation condition in actual forming. Therefore, the test method can only obtain the yield and flow behavior test data of the plate under a fixed main stress ratio or simple variable stress ratio path, and cannot be used for guiding a complex forming process that the main stress ratio and the stress main shaft in a plane are continuously and non-linearly changed at the same time.
In the existing metal sheet liquid pressure bulging device, the lower surface of a bulging female die is often directly contacted with the upper surface of a force application piston of a sealing force application device, and when the parallelism of the two surfaces is low, the sealing failure in the bulging process is directly caused, and the experiment fails. When the wall thickness of the sheet metal blank is large, the sealing requires a large trimming force, and the force-exerting piston is required to have a very high tonnage. In addition, the lower die is easy to topple when the piston descends, and the safety and stability of the bulging device are low.
To sum up, in order to accurately describe the deformation behavior of the metal sheet under the nonlinear loading condition of the rotation of the stress spindle, measure the stress and strain data in the whole process, and be used for evaluating the forming performance of the metal sheet material under the complex loading condition, guiding the determination of the actual forming process parameters, and improving the safety stability and sealing capability of the bulging device, a metal sheet bulging test device and a method capable of realizing the continuous rotation of the stress spindle need to be established.
Disclosure of Invention
The invention aims to solve the problems that the existing sheet metal performance test method can only change the stress ratio of a measuring point in a plate surface by changing a simple loading force or a boundary condition, and can not realize the rotation of a stress main shaft, so that the non-proportional loading material performance parameters which are closer to an actual forming process and can be used for accurately guiding the determination of forming process parameters can not be obtained, and the safety stability and sealing capability of the existing bulging device are lower, and further provides the sheet metal bulging test device and method capable of realizing the continuous rotation of the stress main shaft.
The technical principle of the invention is expressed as follows:
the invention changes the constraint boundary condition of the metal sheet pole in the bulging process by changing the axial length ratio value and the length axial direction of the ellipse of the upper die cross section of the rotary female die, thereby realizing the change of the primary and secondary stress direction and the size in the plane of the metal sheet pole in bulging. According to the geometric characteristics of the upper die cavity of the rotary die, when the pole of the metal sheet expands to any height in the rotary die, the boundary constraint shape is elliptical, and the geometric shape of the expansion area can be approximately the ellipsoid of rotation. In order to explain the technical principle of the rotating die, the following will explain by a stress analysis chart and an outline chart of the bulging zone when the bulging height of the vertex of the bulging zone of the metal sheet in the rotating die is H and the height difference between the upper die constraint boundary of the rotating die and the inlet of the die cavity is H as shown in fig. 5 (a) and 5 (b).
The geometric shape of the metal sheet in the bulging process is approximately a rotary ellipsoid, an ellipsoid rotation axis is parallel to the long axis direction of an ellipse constraint boundary of an upper die of a rotary female die, stress analysis is carried out on the surface pole P of the metal sheet, and a stress balance equation is obtained:
wherein p is the bulging pressure at the moment, and t is the pole wall thickness. ρ θ And
radius of curvature at the pole along the major and minor axes of the mold cavity on the rotating die, l θ And->
The lengths in the x and y directions at the poles, σ, respectively θ And->
Stress components at the poles along the major and minor axes, respectively.
Simplifying the formula (1) to obtain a Laplace equation:
in-plane principal stress sigma at the point of the sheet metal bulging zone 1 Sum of in-plane secondary stresses sigma 2 Can be communicated withCalculated by the following formula:
as can be seen from the above (2), when the metal sheet swells in the rotary die, the direction of the primary and secondary stresses in the plane at the poles depends on the direction of the long and short axes of the boundary ellipse at the moment, so that the rotation of the primary and secondary stresses in the plane at the poles can be realized by rotating the long and short axes of the boundary ellipse in the direction of the swelling height; the ratio of principal to secondary stresses in the plane at the pole can be changed by changing the axial length ratio of the ellipse.
Furthermore, based on the volume invariant assumption, the P-point wall thickness can be calculated by:
wherein t is 0 Is the initial wall thickness of the sheet metal.
And->
The strain in the long and short axis directions of the elliptical boundary of the cross section of the model cavity on each instantaneous rotating female die can be obtained through recording of a data acquisition system.
The technical scheme of the invention is as follows: the metal sheet bulging test device capable of realizing continuous rotation of a stress main shaft comprises a rotary female die upper die 5, a rotary female die lower die 6, a sealing force application system 18, a pressure medium output system 15, a data acquisition system 1, a control system 13 and a support frame;
the control system 13 is respectively connected with the data acquisition system 1, the pressure medium output system 15 and the sealing force application system 18;
the data acquisition system 1 is positioned above the supporting frame and is used for acquiring images;
a rotary female die upper die 5, a rotary female die lower die 6, a liquid filling pressure plate 7 and a liquid filling pressure plate backing plate 8 are sequentially arranged in the support frame from top to bottom; the liquid filling pressure plate 7 and the liquid filling pressure plate backing plate 8 respectively move up and down through a pressure plate ejection mechanism 11 and a backing plate ejection mechanism 10; one end of a pressure medium output system 15 is connected with the liquid filling pressing plate 7 through a pressure medium output high-pressure hose 14 for transmitting a high-pressure medium 19 for bulging, and the other end of the pressure medium output system is connected with the control system 13 through a pressure sensor 16 for transmitting a pressure value; the seal force application system 18 is respectively connected with the pressing plate ejection mechanism 11 and the backing plate ejection mechanism 10 through a seal force application liquid medium high-pressure hose 17 and is used for transmitting a seal force application liquid medium 21; a cavity is formed in the rotary female die upper die 5, the cavity is a through elliptical hole which is gradually reduced from bottom to top along the height direction and gradually rotates in the horizontal plane along the long and short axis direction, and the axial length ratio of the elliptical hole is unchanged or continuously changed at the same time according to the material performance test requirement; one end of the upper die 5 of the rotary female die is connected with the supporting frame, and is fixedly connected with an upper backing plate of the supporting frame by bolts; the outer edge of the other end is sequentially provided with a circular semicircular groove and a zigzag concave-convex groove; the lower die 6 of the rotary female die is arranged on the liquid-filled pressing plate backing plate 8, semicircular convex ribs and zigzag concave-convex grooves are arranged at the outer edge of the lower die and matched with the upper die 5 of the rotary female die for use, the metal sheet 23 is placed between the upper die 5 of the rotary female die and the lower die 6 of the rotary female die and is tightly pressed, and edge pressing is realized on the metal sheet 23 in bulging deformation;
the liquid filling pressing plate 7 is a stepped cylinder, a through hole is formed in the liquid filling pressing plate, and the through hole is communicated with the pressure medium output high-pressure hose 14; the liquid-filled pressing plate 7 comprises an upper layer large-diameter cylinder and a lower layer small-diameter cylinder; the upper surface of the upper layer large-diameter cylinder is provided with an O-shaped ring groove 20 for placing an O-shaped sealing ring; after the clamping and edge pressing of the metal sheet are completed, the liquid filling pressing plate 7 moves upwards to be in contact with the metal sheet 23, then pressure is continuously applied, and the O-shaped sealing ring is deformed and sealed; the lower layer small diameter cylinder is nested in a stepped hole arranged on the liquid filling pressure plate backing plate 8, so that the liquid filling pressure plate 7 is prevented from sliding out to topple over when the piston of the pressure plate ejection mechanism 11 descends too low, and the stability of the whole device is improved.
The design purpose of the liquid filling pressure plate backing plate 8 is to fix the rotary die lower die 6, and the reliable blank holder force can be provided when the wall thickness of the plate to be tested is thicker or the circumferential direction is uneven, so that the sealing capability of the device is improved.
The metal sheet bulging test device capable of realizing continuous rotation of the stress main shaft further comprises a heating system 22 which is arranged at the outer edge of the lower die 6 of the rotary female die; after the induction coil of the heating system 22 is wound with the heat insulation material, the induction coil is placed on the liquid filling pressure plate backing plate 8 through the insulation material; when the high Wen Zhangxing is employed, the high-pressure medium 19 for bulging is a high-pressure gas medium.
The support frame comprises an upper base plate 4, a lower base plate 12, a support pull rod 9, an acrylic plate 2 and a cushion block 3; the center of the upper backing plate 4 is provided with an inverted trapezoid through hole window which is larger than the maximum cross section of the upper die 5 cavity of the rotary female die and is used for shooting speckles in the bulging area on the surface of the metal sheet by a CCD camera of the data acquisition system 1; an acrylic plate 2 is arranged above the upper backing plate 4 through a cushion block 3 and is used for preventing liquid from splashing to pollute and damage a lens of the CCD camera when the metal sheet is burst; the upper cushion plate 4 and the lower cushion plate 12 are connected through a supporting pull rod 9. The upper backing plate 4 and the lower backing plate 12 have the same external dimensions, countersunk threaded holes are formed in the periphery, and the countersunk threaded holes are matched and locked with the supporting pull rod 9 through inner hexagon bolts.
The cavity of the rotary female die upper die 5 is opposite to the CCD camera lens of the data acquisition system 1 and is used for acquiring deformation data of the vertex of the bulging area of the metal sheet 23 in real time in the bulging process; the control system 13 is connected with the data acquisition system 1, and the control system 13 gives a start and end instruction of data acquisition to the data acquisition system 1 and stores and post-processes the data;
the pressure medium output system 15 is started under the instruction of the control system 13, and the high-pressure medium 19 for bulging with specific pressure is conveyed to the liquid filling pressing plate 7 through the pressure medium output high-pressure hose 14 according to a preset pressurization curve to perform bulging test.
A sheet metal bulging test method capable of realizing continuous rotation of a stress main shaft comprises the following specific steps:
designing an upper rotary die 5 and a lower rotary die 6 according to the change requirements of two main stress directions and numerical values on the vertexes of a bulging zone of a metal sheet, calculating the main stress at the vertexes in the bulging test process by using a theoretical model and a numerical simulation model, and determining the cavity shapes and the sizes of the upper rotary die 5 and the lower rotary die 6, the bulging pressure change path and the blank holder force;
step two, manufacturing an upper rotary die 5 and a lower rotary die 6, and smearing lubricant in the cavity of the upper rotary die 5 to reduce the influence of friction force on the stress of the bulging area; cutting a metal sheet according to the outer diameter sizes of the upper die 5 and the lower die 6 of the rotary female die, and spraying speckles on one side of the surface of the metal sheet;
step three, connecting the control system 13 with the seal force application system 18, the data acquisition system 1 and the pressure medium output system 15; the pressure medium output system 15 and the liquid filling pressure plate 7 are connected through a pressure medium output high-pressure hose 14; setting a hydraulic change path and a blank holder force in the test process in a control system 13; according to the initial direction that the material direction of the metal sheet 23 forms a set angle with the long axis at the inlet of the cavity of the upper die 5 of the rotary die, the speckle side faces the upper die 5 of the rotary die, the metal sheet 23 is placed between the upper die 5 of the rotary die and the lower die 6 of the rotary die, and the sealing force application system 18 is started; the liquid filling pressing plate backing plate 8 ascends, and the metal sheet deforms under the action of the semicircular convex ribs of the lower die 6 of the rotary female die and the semicircular grooves of the upper die 5 of the rotary female die to finish edge pressing; the liquid filling pressing plate 7 moves upwards, the upper surface of the liquid filling pressing plate is contacted with the metal sheet 23, then pressure is continuously applied, and the O-shaped sealing ring is deformed to realize sealing; simultaneously starting the backing plate ejection mechanism 10 and the pressing plate ejection mechanism 11 of the sealing force application system 18, collecting the blank pressing force by the sealing force application system 18, transmitting the blank pressing force to the control system 13, and stopping the actions of the backing plate ejection mechanism 10 and the pressing plate ejection mechanism 11 after the blank pressing force value displayed by the control system 13 reaches a preset value; a data acquisition system 1 is arranged right above the window of the upper base plate 4 for data acquisition;
operating the control system 13, starting the pressure medium output system 15 to enable the metal sheet 23 to stably generate stress main shaft continuous rotation bulging deformation under the action of the high-pressure medium 19 for bulging, and recording and storing bulging pressure in the control system 13 in real time; the data acquisition system 1 synchronously records displacement, strain, wall thickness and contour curvature of the vertex of the bulging zone in the whole test process;
step five, after the deformation degree of the vertex of the bulging area and the high-pressure liquid pressure reach the preset maximum value or the metal sheet is broken, the operation control system 13 ends the test and relieves pressure, the CCD camera is closed, and test data are stored; the liquid filling pressing plate 7 descends, and the expanded metal sheet 23 is disassembled and taken out;
and step six, substituting the peak strain and curvature radius of the bulging area of the metal sheet obtained in the bulging test process of the rotary female die and the corresponding bulging pressure into a theoretical model, calculating to obtain a stress-strain curve, a Rode coefficient change curve and the like of the peak of the bulging area of the metal sheet under a specific main stress direction rotation path, and establishing a constitutive equation.
The beneficial effects of the invention are as follows:
1. the metal sheet bulging test device and method capable of realizing continuous rotation of the stress main shaft can establish an accurate constitutive model of the metal sheet under the condition of being closer to an actual forming process. In actual forming, the boundary constraint condition of the metal sheet changes in real time, and the material direction and the stress main axis direction in the plate surface also change in a complex way. In the current complex special-shaped thin-wall component forming, the method is widely applied to the constitutive model established by the test under the fixed main stress ratio or simple variable stress ratio path to guide parameter determination, and the brand new bulging test method provided by the invention can realize continuous rotation of the stress main shaft on the basis of the variable stress ratio, so that the method is closer to the actual forming process, and the constructed constitutive model can obviously improve the guiding precision of the actual forming.
2. According to the metal sheet bulging test device and method capable of realizing continuous rotation of the stress main shaft, the rotation path of the stress main shaft, the size change path, the initial included angle between the metal sheet material direction and the stress main shaft direction can be adjusted according to actual requirements, the metal sheet bulging test device and method can be arbitrarily selected, the flexibility is high, and the range of parameters which can be realized is wide. The in-plane principal and subordinate stress direction and the size of the vertex of the bulging zone of the sheet metal can be flexibly changed only through the shape and size design of the elliptic section of the mould cavity on the rotary female mould and the material direction setting of the sheet metal. In addition, in the aspect of design of a model cavity on the rotary female die, the length axis direction and the axial length ratio of the cross section ellipse can be flexibly selected within a large range of 0-60 degrees and 0.4-1 degrees respectively; in the aspect of the material direction of the metal sheet, the initial rolling direction of the sheet is taken as a reference, and the included angle between the material direction with any angle and the long axis direction of the inlet of the upper model cavity can be selected at random within 0-90 degrees. The parameter setting range comprises the stress ratio, the stress direction and the included angle change range of the material and the direction of the die, which are experienced by the metal sheet in the forming of most of complex special-shaped thin-wall components, so that the invention can meet the requirement of large-scale parameter setting.
3. The metal sheet bulging test device and method capable of realizing continuous rotation of the stress main shaft provided by the invention have strong adaptability, wide variety of applicable metal materials and good popularization and application prospects. For a metal plate blank with good plasticity and thinner wall thickness, normal-temperature hydraulic bulging can be directly carried out; for a metal plate blank with poor plasticity and thicker wall thickness or with test requirements at different temperatures, a heating device is added on the periphery of a die on the basis of a normal-temperature bulging device, a liquid pressure medium is changed into gas, hot state pneumatic bulging is carried out, and stress main shaft rotation nonlinear loading deformation behavior data of the metal plate at different temperatures can be obtained.
4. The combined form of the rotary female die lower die, the liquid filling pressure plate base plate, the pressure plate ejection mechanism and the base plate ejection mechanism can prevent the liquid filling pressure plate from sliding out to topple when the piston of the pressure plate ejection mechanism is lowered too low, can provide larger blank holding force when the wall thickness of a plate to be tested is thicker or the circumferential direction is uneven, and can obviously improve the safety stability and the sealing capability of the whole device. In addition, the additional arrangement of the backing plate ejection mechanism can apply blank holder force together with the pressing plate ejection mechanism during blank holder sealing, so that the tonnage requirement of the pressing plate ejection mechanism during thicker plate sealing is reduced.
5. According to the metal sheet bulging test device and method capable of realizing continuous rotation of the stress main shaft, provided by the invention, the transfer condition of the hardening zone and the main deformation zone in the plane of the plate can be obtained by collecting the change information of the strain cloud image in the plane of the test plate when the material direction and the stress main shaft direction continuously and complexly change, and the process preforming steps are reasonably arranged according to the transfer condition, so that the wall thickness uniformity and the comprehensive performance of formed parts are improved.
Drawings
FIG. 1 (a) is a schematic diagram of a normal temperature bulging principle of a sheet metal bulging test device capable of realizing continuous rotation of a stress main shaft;
FIG. 1 (b) is a cross-sectional view of the region A in FIG. 1 (a);
FIG. 2 (a) is a schematic diagram of a metal sheet bulging test apparatus capable of realizing continuous rotation of a stress spindle according to the principle of high Wen Zhangxing;
FIG. 2 (B) is a cross-sectional view of region B of FIG. 2 (a);
FIG. 3 (a) is a schematic diagram of the upper die of a rotary female die with equal axial length ratio;
FIG. 3 (b) is a perspective view of the upper die of the rotary die with equal axial length ratio at different bulging heights;
FIG. 3 (c) is a schematic view of an elliptical cross section of the entrance of the mold cavity on the isometric length-ratio rotary die, at a height h from the entrance of the cavity 0 =0, ellipse principal axis rotation angle θ 0 ＝0；
FIG. 3 (d) is the mold cavity height h of the equiaxial length ratio rotary die 1 An elliptical cross section is shown at a height h from the cavity entrance 1 >0, ellipse principal axis rotation angle θ 1 >0；
FIG. 3 (e) is the mold cavity height h on the isometric length-ratio rotary die 2 An elliptical cross section is shown at a height h from the cavity entrance 2 >h 1 Rotation angle theta of elliptic main shaft 2 >θ 1 ；
FIG. 3 (f) is a schematic view of an elliptical cross section at the exit of the mold cavity on an isometric length-ratio rotating female mold, at a height h from the entrance of the mold cavity f >h 2 Rotation angle theta of elliptic main shaft f >θ 2 ；
FIG. 4 (a) is a schematic diagram of the upper die of the rotary die with variable axial length ratio;
FIG. 4 (b) is a perspective view of the upper die of the rotary female die with variable axial length ratio at different bulging heights;
FIG. 4 (c) is a schematic view of an elliptical cross section of the inlet of the mold cavity on the rotary die with a variable axial length ratio, at a height h from the inlet of the cavity 0 =0, ellipse principal axis rotation angle θ 0 ＝0；
FIG. 4 (d) shows a rotation of the variable axial length ratioHeight h of upper die cavity of female die 1 An elliptical cross section is shown at a height h from the cavity entrance 1 >0, ellipse principal axis rotation angle θ 1 >0；
FIG. 4 (e) is a model cavity height h on a rotary die with a variable axial length ratio 2 An elliptical cross section is shown at a height h from the cavity entrance 2 >h 1 Rotation angle theta of elliptic main shaft 2 >θ 1 ；
FIG. 4 (f) is a schematic view of an elliptical cross section at the outlet of the mold cavity on a rotary die with a variable axial length ratio, at a height h from the inlet of the die cavity f >h 2 Rotation angle theta of elliptic main shaft f >θ 2 ；
FIG. 5 (a) is a force analysis chart of the bulging height h of the metal sheet bulging zone apexes in the rotating die;
fig. 5 (b) is an outer profile of the bulging zone when the bulging height of the metal sheet bulging zone apexes in the rotating die is h.
The device comprises a data acquisition system 1, an acrylic plate 2, a cushion block 4, an upper backing plate 5, a rotary female die upper die 6, a rotary female die lower die 7, a liquid filling pressing plate 8, a liquid filling pressing plate backing plate 9, a supporting pull rod 10, a backing plate ejection mechanism 11, a pressing plate ejection mechanism 12, a lower backing plate 13, a control system 14, a pressure medium output high-pressure hose 14, a pressure medium output system 15, a pressure sensor 16, a sealing force application liquid medium high-pressure hose 17, a sealing force application system 18, a bulging high-pressure medium 19, an O-shaped ring groove 20, a sealing force application liquid medium 21, a heating system 22 and a metal sheet 23.
Detailed Description
The following describes the embodiments of the present invention further with reference to the drawings and technical schemes.
The first embodiment is as follows: referring to fig. 1 and 3, the metal sheet bulging test device and method capable of realizing continuous rotation of a stress spindle according to the present embodiment are realized by the following steps:
designing an upper rotary die 5 and a lower rotary die 6 according to path change requirements of two main stress directions on the vertexes of a bulging area of a metal sheet, calculating main stress at the vertexes in the bulging test process by using a theoretical model, establishing a numerical model for simulation calculation, determining whether the strength of an upper backing plate 4, a supporting pull rod 9 and a lower backing plate 12 meets the test requirement or not according to the included angle between the initial material direction and the cavity inlet of the upper rotary die 5, the equal ratio reduction ratio of the cavity section of the upper rotary die 5 in the bulging height direction, the pressure change path of a high-pressure medium 19 for bulging and variables such as sealing blank holding force provided by the upper rotary die 5, the lower rotary die 6 and the liquid-filled pressure plate backing plate 8.
And step two, manufacturing an upper rotary die 5 and a lower rotary die 6, and coating lubricant in the cavity of the upper rotary die 5 to reduce the influence of friction force on the stress of the bulging area. The test sheet metal 23 is obtained by cutting according to the outer diameter dimensions of the upper die 5 and the lower die 6 of the rotary die, and after the surface of the slab is cleaned, speckles are sprayed on one side of the slab.
And thirdly, placing the metal sheet 23 between the upper rotary die 5 and the lower rotary die 6 according to the specific initial angle between the material direction of the metal sheet 23 and the long axis at the inlet of the upper rotary die 5 and keeping the speckle side towards the upper rotary die 5. The control system 13 is connected with the data acquisition system 1, the pressure medium output system 15 and the seal force application system 18 by setting a hydraulic change path and a blank holder force in the test process. The control system 13 is operated, the backing plate ejection mechanism 10 is started, the liquid filling pressing plate backing plate 8 is moved upwards to drive the rotary die lower die 6 to move upwards, and the metal sheet 23 deforms between the annular groove of the rotary die upper die 5 and the annular protruding rib of the rotary die lower die 6 to realize edge pressing. The liquid filling pressing plate 7 moves upwards, the upper surface of the liquid filling pressing plate is contacted with the metal sheet 23, then pressure is continuously applied, and the O-shaped sealing ring which is placed in the O-shaped sealing ring groove 20 in advance deforms until sealing is achieved. Simultaneously starting the sealing force application system 18 and the plate ejection mechanism 10 and the plate ejection mechanism 11 to seal the edge pressing force of the force application system 18, transmitting the edge pressing force to the control system 13, and stopping the actions of the plate ejection mechanism 10 and the plate ejection mechanism 11 after the edge pressing force value displayed by the control system 13 reaches a preset value; the data acquisition system 1 is arranged right above the window of the upper base plate 4, and a pressure medium output high-pressure hose 17 is used for connecting the pressure medium output system 15 and the liquid filling pressure plate 7.
And step four, operating the control system 13, starting the pressure medium output system 15, enabling the metal sheet 23 to stably generate continuous rotary bulging deformation of the stress main shaft according to a preset pressure path under the action of the high-pressure medium 19 for bulging, and recording and storing the bulging pressure in the control system 13 in real time. The high-pressure medium 19 for bulging used in the room-temperature test is usually a liquid medium such as high-pressure water or oil. And in the whole test process, the displacement, strain, wall thickness, contour curvature and other data of the vertex of the bulging zone are synchronously recorded by using the data acquisition system 1.
And fifthly, after the deformation degree of the top of the bulging area of the metal sheet 23 and the high-pressure liquid pressure reach the preset maximum value or burst, the operation control system 13 ends the test, removes the high-pressure medium 19 for bulging in the pressure medium output system 15, closes the data acquisition system 1 and saves test data. The seal force application system 18 is started to carry out unloading action, and the liquid filling pressure plate 7 and the liquid filling pressure plate backing plate 8 simultaneously descend to drive the rotary die 6 to descend, and the expanded metal sheet 23 is detached.
And step six, substituting the data parameters such as the bulging area vertex strain and curvature radius of the metal sheet 23 obtained in the bulging test process of the rotary die, the corresponding bulging pressure and the like into a theoretical model, calculating to obtain a stress-strain curve, a Rode coefficient change curve and the like of the metal sheet bulging area vertex under a specific main stress direction rotation path, and establishing a constitutive equation. And (5) storing strain cloud pictures of the bulging area, and analyzing the transfer condition of the hardening area and the main deformation area in the plane of the plate in the bulging process.
The beneficial effects of this embodiment are: the metal sheet bulging test method and device with the stress main shaft continuously rotating can establish an accurate constitutive model of the metal sheet under the condition of being closer to the actual forming process, and the guiding precision of actual forming is obviously improved. The direction of the long axis and the short axis of the cross section ellipse can be flexibly selected within a large range of 0-60 degrees, and the included angle between the direction of the initial material and the long axis direction of the inlet of the upper model cavity can be arbitrarily selected within a range of 0-90 degrees, so that the requirement of large-range parameter setting can be met. According to the embodiment, the transfer condition of the hardening zone and the main deformation zone in the plane of the plate can be obtained through collecting the change information of the strain cloud image in the plane of the plate in the test when the material direction and the stress main axis direction continuously and complexly change, and the process preforming step is reasonably set according to the transfer condition, so that the wall thickness uniformity and the comprehensive performance of the formed part are improved. The sealing mode adopted by the embodiment can obviously improve the safety stability and sealing capability of the whole device and obviously reduce the tonnage requirement on the pressing plate ejection mechanism.
The second embodiment is as follows: referring to fig. 1 and 4, the metal sheet bulging test apparatus and method capable of continuously rotating a stress spindle according to the present embodiment is based on the design of the rotary die upper die 5 according to the first embodiment, and the rotary die upper die 5 is designed as a variable axial length ratio rotary die by considering the changes of the primary and secondary stress directions and the magnitudes at the vertices of the bulging area of the metal sheet 23. Other steps and parameters are the same as in the first embodiment.
The beneficial effects of this embodiment are: compared with the upper die of the rotary female die with the equal axial length ratio, which is provided in the first specific embodiment and can only realize the rotation of the pole stress main shaft of the bulging zone, the upper die of the rotary female die with the variable axial length ratio, which is provided in the first specific embodiment, can also realize the synchronous change of the primary and secondary stress ratio in the pole surface of the bulging zone within the range of 0.4-1 in the bulging process, widens the application range of the bulging test of the rotary female die, and is more close to the in-plane primary and secondary stress change path in the actual forming process of the complex special-shaped thin-wall component.
And a third specific embodiment: referring to fig. 2 and 3, the metal sheet bulging test device and method capable of realizing continuous rotation of the stress spindle according to the present embodiment are provided, in which, based on the test device set in the first embodiment, a heating system 22 is additionally provided on the outer edge of the lower die 6 of the rotary die in the second step of the first embodiment, a heat insulating material is wound around the induction coil of the heating system 22 and placed on the liquid-filled platen pad 8, and the two are separated by using an insulating material. And starting a heating system 22, heating the die to a set temperature in a die closing state without placing the metal sheet, preserving heat, opening the die after the temperature is stable, placing the metal sheet and realizing sealing according to the step III of the specific embodiment, and starting the bulging test according to the step IV of the specific embodiment after the temperature displayed in the heating system 22 is stabilized at the target test temperature again. In this embodiment, since the high pressure Wen Zhangxing method is adopted, the high pressure medium 19 for bulging used in the test is a high pressure gas medium. After the test is completed, the heating system 22 is turned off and powered off, and then the unloading and data processing are performed according to the other steps and parameters of the first embodiment. Other steps and parameters are the same as in the first embodiment.
The beneficial effects of this embodiment are: in contrast to the normal-temperature rotating die bulging test set forth in the first embodiment, in this embodiment, an induction heating device is added to expand the temperature range of the rotating die bulging test from normal temperature to high temperature. The high-temperature rotating die bulging test method and the device are suitable for manufacturing the part metal material by adopting the poor plasticity and the thermal state pneumatic bulging at normal temperature, so that the rotating die bulging test method and the device have strong adaptability, can be widely applied to metal material types, and have good popularization and application prospects.
Claims (5)
1. The metal sheet bulging test device capable of realizing continuous rotation of a stress main shaft is characterized by comprising a rotary female die upper die (5), a rotary female die lower die (6), a sealing force application system (18), a pressure medium output system (15), a data acquisition system (1), a control system (13) and a supporting frame;
the control system (13) is respectively connected with the data acquisition system (1), the pressure medium output system (15) and the sealing force application system (18);
the data acquisition system (1) is positioned above the supporting frame and is used for acquiring images;
an upper rotary die (5), a lower rotary die (6), a liquid filling pressure plate (7) and a liquid filling pressure plate backing plate (8) are sequentially arranged in the support frame from top to bottom; the liquid filling pressing plate (7) and the liquid filling pressing plate backing plate (8) respectively move up and down through a pressing plate ejection mechanism (11) and a backing plate ejection mechanism (10); one end of a pressure medium output system (15) is connected with the liquid filling pressing plate (7) through a pressure medium output high-pressure hose (14) and is used for transmitting a high-pressure medium (19) for bulging, and the other end of the pressure medium output system is connected with a control system (13) through a pressure sensor (16) and is used for transmitting a pressure value; the sealing force application system (18) is respectively connected with the pressing plate ejection mechanism (11) and the backing plate ejection mechanism (10) through a sealing force application liquid medium high-pressure hose (17) and is used for transmitting a sealing force application liquid medium (21); a cavity is formed in the rotary female die upper die (5), the cavity is a through elliptical hole which gradually reduces from bottom to top along the height direction and gradually rotates in the horizontal plane along the long and short axis direction, and the axial length ratio of the elliptical hole is unchanged or continuously changed at the same time; one end of the upper die (5) of the rotary female die is connected with the supporting frame, and the outer edge of the other end of the upper die is sequentially provided with a circular semicircular groove and a zigzag concave-convex groove; the lower die (6) of the rotary female die is arranged on the liquid-filled pressing plate backing plate (8), semicircular convex ribs and zigzag concave-convex grooves are arranged at the outer edge of the lower die and are matched with the upper die (5) of the rotary female die for use, the metal sheet (23) is placed between the upper die (5) of the rotary female die and the lower die (6) of the rotary female die and is pressed, and edge pressing is achieved on the metal sheet (23) in bulging deformation;
the liquid filling pressing plate (7) is a stepped cylinder, a through hole is formed in the liquid filling pressing plate, and the through hole is communicated with the pressure medium output high-pressure hose (14); the liquid filling pressing plate (7) comprises an upper layer large-diameter cylinder and a lower layer small-diameter cylinder; the upper surface of the upper layer large-diameter cylinder is provided with an O-shaped ring groove (20) for placing an O-shaped sealing ring; after the clamping and edge pressing of the metal sheet are completed, the liquid filling pressing plate (7) moves upwards to be in contact with the metal sheet (23) and then continuously applies pressure, and the O-shaped sealing ring is deformed and sealed; the lower layer small diameter cylinder is nested in a stepped hole arranged on the liquid filling pressure plate backing plate (8).
2. The sheet metal bulging test apparatus capable of realizing continuous rotation of a stress spindle according to claim 1, further comprising a heating system (22) provided at an outer edge of the lower die (6) of the rotary die; after the induction coil of the heating system (22) is wound with a heat insulation material, the induction coil is placed on the liquid filling pressing plate base plate (8) through the insulation material; when the high Wen Zhangxing is used, the high pressure medium (19) for bulging is a high pressure gas medium.
3. The sheet metal bulging test device capable of realizing continuous rotation of a stress main shaft according to claim 1 or 2, wherein the support frame comprises an upper base plate (4), a lower base plate (12), a support pull rod (9), an acrylic plate (2) and a cushion block (3); the center of the upper backing plate (4) is provided with an inverted trapezoid through hole window which is larger than the maximum section of the cavity of the upper die (5) of the rotary female die, and the inverted trapezoid through hole window is used for shooting speckles in the bulging area on the surface of the metal sheet by a CCD camera of the data acquisition system (1); an acrylic plate (2) is arranged above the upper base plate (4) through a cushion block (3) and is used for preventing liquid from splashing to pollute and damage a lens of the CCD camera when the metal sheet is broken; the upper base plate (4) and the lower base plate (12) are connected through a supporting pull rod (9).
4. The metal sheet bulging test device capable of realizing continuous rotation of a stress main shaft according to claim 3, wherein a cavity of the rotating female die upper die (5) is opposite to a CCD camera lens of the data acquisition system (1) and is used for acquiring deformation data of the vertex of a bulging area of the metal sheet (23) in real time in the bulging process; the control system (13) is connected with the data acquisition system (1), and the control system (13) gives a start and end instruction of data acquisition to the data acquisition system (1) and stores and post-processes the data;
the pressure medium output system (15) is started under the command sent by the control system (13), and a high-pressure medium (19) for bulging with specific pressure is conveyed into the liquid filling pressure plate (7) through the pressure medium output high-pressure hose (14) according to a preset pressurizing curve to perform bulging test.
5. A sheet metal bulging test method capable of realizing continuous rotation of a stress main shaft is characterized by comprising the following specific steps:
designing an upper rotary die (5) and a lower rotary die (6) according to the change requirements of two main stress directions and numerical values on the vertexes of a bulging area of a metal sheet, calculating the main stress at the vertexes in the bulging test process by using a theoretical model and a numerical simulation model, and determining the cavity shapes and the sizes of the upper rotary die (5) and the lower rotary die (6), the bulging pressure change path and the blank holder force;
step two, manufacturing an upper rotary die (5) and a lower rotary die (6), and coating lubricant in the cavity of the upper rotary die (5) for reducing the influence of friction force on the stress of the bulging area; cutting a metal sheet according to the outer diameter sizes of the upper die (5) and the lower die (6) of the rotary female die, and spraying speckles on one side of the surface of the metal sheet;
step three, connecting the control system (13) with the sealing force application system (18), the data acquisition system (1) and the pressure medium output system (15); a pressure medium output system (15) and a liquid filling pressing plate (7) are connected through a pressure medium output high-pressure hose (14); setting a hydraulic change path and a blank holder force in a test process in a control system (13); according to the initial direction that the material direction of the metal sheet (23) and the long axis at the cavity entrance of the upper die (5) of the rotary die form a set angle, the speckle side faces the upper die (5) of the rotary die, the metal sheet (23) is put between the upper die (5) of the rotary die and the lower die (6) of the rotary die, and a sealing force application system (18) is started; the liquid filling pressing plate backing plate (8) ascends, and the metal sheet deforms under the action of the semicircular convex ribs of the rotary female die lower die (6) and the semicircular grooves of the rotary female die upper die (5) to finish edge pressing; the liquid filling pressing plate (7) moves upwards, the upper surface of the liquid filling pressing plate is contacted with the metal sheet (23) and then pressure is continuously applied, and the O-shaped sealing ring is deformed to realize sealing; simultaneously starting a backing plate ejection mechanism (10) and a pressing plate ejection mechanism (11) of a sealing force application system (18), collecting blank pressing force by the sealing force application system (18), transmitting the blank pressing force to a control system (13), and stopping the actions of the backing plate ejection mechanism (10) and the pressing plate ejection mechanism (11) after the blank pressing force value displayed by the control system (13) reaches a preset value; a data acquisition system (1) is arranged right above the window of the upper base plate (4) for data acquisition;
operating the control system (13), starting the pressure medium output system (15), enabling the metal sheet (23) to stably generate stress main shaft continuous rotation bulging deformation under the action of the high-pressure medium (19) for bulging, and recording and storing bulging pressure in the control system (13) in real time; the data acquisition system (1) synchronously records the displacement, strain, wall thickness and contour curvature of the vertex of the bulging zone in the whole test process;
step five, after the deformation degree of the vertex of the bulging area and the high-pressure liquid pressure reach the preset maximum value or the metal sheet is broken, the operation control system (13) ends the test and relieves pressure, the CCD camera is closed, and test data are stored; the liquid filling pressing plate (7) descends, and the expanded metal sheet (23) is disassembled and taken out;
and step six, substituting the peak strain and curvature radius of the bulging area of the metal sheet obtained in the bulging test process of the rotary female die and the corresponding bulging pressure into a theoretical model, calculating to obtain a stress-strain curve, a Rode coefficient change curve and the like of the peak of the bulging area of the metal sheet under a specific main stress direction rotation path, and establishing a constitutive equation.
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| CN202310359195.8A CN116429590A (en) | 2023-04-06 | 2023-04-06 | Metal sheet bulging test device and method capable of realizing continuous rotation of stress main shaft |
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| CN202310359195.8A CN116429590A (en) | 2023-04-06 | 2023-04-06 | Metal sheet bulging test device and method capable of realizing continuous rotation of stress main shaft |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117019960A (en) * | 2023-08-16 | 2023-11-10 | 中国航发贵州黎阳航空动力有限公司 | Weld-free forming method of large-size ultrathin-wall superalloy sealing sheet |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117019960A (en) * | 2023-08-16 | 2023-11-10 | 中国航发贵州黎阳航空动力有限公司 | Weld-free forming method of large-size ultrathin-wall superalloy sealing sheet |
| CN117019960B (en) * | 2023-08-16 | 2024-04-09 | 中国航发贵州黎阳航空动力有限公司 | Weld-free forming method of large-size ultrathin-wall superalloy sealing sheet |
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