CN116933426A - Method and system for predicting and controlling cold roll forming resilience of corrugated groove profile - Google Patents

Method and system for predicting and controlling cold roll forming resilience of corrugated groove profile Download PDF

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CN116933426A
CN116933426A CN202310934787.8A CN202310934787A CN116933426A CN 116933426 A CN116933426 A CN 116933426A CN 202310934787 A CN202310934787 A CN 202310934787A CN 116933426 A CN116933426 A CN 116933426A
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rebound
corrugated
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corrugated groove
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卫奕凡
胡雪燕
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China Shipbuilding Power Group Co ltd
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Abstract

The invention discloses a method and a system for predicting and controlling rebound quantity of cold roll forming of corrugated groove profiles. A prediction control method for a cold roll forming resilience model of a corrugated groove profile comprises the following steps: s1: constructing a three-dimensional assembly model based on the geometric dimensions of the corrugated channel profile; s2: importing the three-dimensional assembly model into finite element software, and performing numerical simulation on the rolling forming and rebound processes of the corrugated groove type groove by using the finite element software; s3: establishing a simulation model in finite element software by adopting a dynamic-static combined algorithm, and predicting the resilience of the corrugated groove profile; s4: and establishing a mathematical model of the rebound quantity by utilizing linear regression analysis according to the rebound quantity predicted in the step S3). And (3) evaluating influence of each process parameter on the rebound quantity by establishing a mathematical model of the rebound quantity and each parameter, so as to predict and control the rebound quantity of the corrugated groove profile.

Description

Method and system for predicting and controlling cold roll forming resilience of corrugated groove profile
Technical Field
The invention relates to the field of metal manufacturing, in particular to a method and a system for predicting and controlling the rebound quantity of cold roll forming of corrugated groove profiles.
Technical Field
The current industrial product aluminum roll support sleeve is mainly made of paper materials, and along with higher and higher requirements on environmental protection control indexes, the manufacturing and using costs of the aluminum roll support sleeve are higher and higher, so that the research on a new material product which is low in cost, environment-friendly and pollution-free and can replace the paper sleeve has important practical value. Compared with the traditional paper sleeve, the aluminum sleeve has the advantages of low cost, high bearing capacity, difficult collapse, environmental protection, no pollution, convenient transportation and management, and the like, and is also convenient for spin forming compared with other metal materials.
The rebound of the aluminum alloy thin-wall corrugated groove profile after forming is largely determined by the forming quality of the sleeve after spinning as an initial product for preparing the aluminum sleeve. At present, most of the multi-groove corrugated plates in the market are formed by adopting a stamping forming process or a hydraulic forming process, and compared with the two processes, the rolling forming process has higher production efficiency, and the manufactured product has better precision and smoothness, thereby meeting the requirements of mass production and high efficiency of modern production. Therefore, the rebound quantity of the multi-groove corrugated plate after being formed can be effectively reduced by determining the proper rolling forming process parameters.
Disclosure of Invention
The invention aims to provide a prediction control method and a prediction control system for cold roll forming resilience of a corrugated groove profile, which are used for solving the problem of high debugging cost of the corrugated groove profile caused by overlarge resilience.
For this purpose, a method for predicting and controlling the rebound quantity of cold roll forming of corrugated groove profiles is provided, which comprises the following steps:
s1: constructing a three-dimensional assembly model based on the geometric dimensions of the corrugated channel profile;
s2: importing the three-dimensional assembly model into finite element software, and performing numerical simulation on the rolling forming and rebound processes of the corrugated groove type groove by using the finite element software;
s3: establishing a simulation model in finite element software by adopting a dynamic-static combined algorithm, and predicting the resilience of the corrugated groove profile;
s4: and establishing a mathematical model of the rebound quantity by utilizing linear regression analysis according to the rebound quantity predicted in the step S3).
S5, according to a mathematical model of the rebound quantity, the rebound quantity is controlled to be minimum by optimizing process parameters.
According to an embodiment of the present invention, in the step S2, numerical simulation of the roll forming and rebound process of the corrugated-grooved groove is implemented in finite element software by setting roll process parameters.
According to one embodiment of the invention, the roll process parameters include bend angle strategy, pass spacing, roll gap spacing, coefficient of friction, and number of formed grooves.
According to one embodiment of the present invention, the three-dimensional assembly model includes an upper roller, a lower roller, and a plate material; the upper roller is a male die, the lower roller is a female die, the structures of the upper roller and the lower roller are mutually matched, and the plate is arranged between gaps of the upper roller and the lower roller.
According to an embodiment of the present invention, in the step S3, the specific step of predicting the rebound amount of the corrugated channel profile includes: and dynamically solving the rolling forming and rebound processes of the corrugated groove profile by utilizing the display, and then importing the solved result into an implicit algorithm to solve the rebound quantity of the corrugated groove profile.
According to an embodiment of the present invention, in the step S3, the prediction of the rebound amount uses the following calculation formula:
α＝θ L +θ R (1)
wherein alpha refers to the rebound quantity; θ denotes the rebound angle; θ L Refers to the maximum rebound angle of the left groove; θ L Refers to the maximum rebound angle of the right side groove; Δz refers to the displacement difference between the two ends of the peak web in the Z-axis direction; ΔY is the peak in the Y-axis directionThe displacement difference at the two ends of the web.
According to one embodiment of the present invention, in the step S4, the mathematical model of the rebound quantity relates to rolling process parameters including a bending angle strategy, a pass pitch, a roll gap pitch, a friction coefficient and a number of forming grooves.
According to one embodiment of the invention, the mathematical model of the rebound quantity is formulated as follows:
α＝22.34-0.5F.C-0.0465I.D-34.34R.G+5.992N-8.364B.A.C (3)
wherein alpha refers to the rebound quantity; 22.34 refers to a constant; F.C means coefficient of friction; I.D refers to the pass interval; R.G the roll gap spacing; n refers to the number of forming grooves; a.c refers to the bend angle strategy.
The invention also provides a prediction control system of the resilience model of the corrugated groove profile, which comprises:
the three-dimensional model building module is used for building a three-dimensional assembly model based on the geometric dimension of the corrugated groove profile;
the numerical simulation module is used for performing numerical simulation on the rolling forming and rebound processes of the corrugated groove type groove;
the resilience amount prediction module is used for predicting the resilience amount of the corrugated groove profile in a simulation model established by adopting a dynamic-static combined algorithm;
and the rebound quantity mathematical model building module is used for building a rebound quantity mathematical model by utilizing linear regression analysis according to the predicted rebound quantity.
According to one embodiment of the invention, the rolling forming and rebound process of the corrugated groove type groove is subjected to numerical simulation, a three-dimensional assembly model is required to be imported into finite element software in advance, and then the numerical simulation of the rolling forming and rebound process of the corrugated groove type groove is realized in the finite element software by setting rolling process parameters; the rolling process parameters comprise bending angle strategies, pass intervals, roll gap intervals, friction coefficients and the number of formed grooves;
the dynamic-static combined algorithm applies finite element software;
the three-dimensional assembly model comprises an upper roller, a lower roller and a plate; the upper roller is a male die, the lower roller is a female die, the structures of the upper roller and the lower roller are mutually matched, and the plate is arranged between gaps of the upper roller and the lower roller;
the prediction of the rebound quantity adopts the following calculation formula:
α＝θ L +θ R (1)
wherein alpha refers to the rebound quantity; θ denotes the rebound angle; θ L Refers to the maximum rebound angle of the left groove; θ L Refers to the maximum rebound angle of the right side groove; Δz refers to the displacement difference between the two ends of the peak web in the Z-axis direction; Δy is the displacement difference at both ends of the peak web in the Y-axis direction;
the mathematical model of the rebound involves rolling process parameters including bending angle strategy, pass spacing, roll gap spacing, coefficient of friction and number of formed grooves.
The invention has the advantages that: the rebound quantity of the corrugated groove profile under each rolling process parameter is predicted through numerical simulation, meanwhile, the rebound quantity and mathematical models of each parameter are established to determine the optimal parameters, the control of the rebound of the corrugated groove profile is achieved, the debugging cost of a rolling forming unit is greatly reduced, meanwhile, the rolling forming quality of the corrugated groove profile is improved, and the method is suitable for the prediction and control of the rebound of aluminum alloy and other alloy multi-groove profiles after forming.
Drawings
FIG. 1 is a flow chart of a method for predicting and controlling the rebound quantity of a corrugated channel profile according to the present invention.
Fig. 2 is a geometric model of the three-dimensional assembly of the present invention (only 3 passes are shown).
FIG. 3 illustrates the transverse bow defect of a corrugated channel profile caused by multi-channel rebound in accordance with the present invention.
FIG. 4 shows a calculation method of the rebound quantity of the corrugated channel profile of the present invention
Detailed Description
The invention will be further described with reference to the drawings and the specific embodiments, but the scope of the invention is not limited thereto.
The invention relates to a prediction control method for a corrugated groove profile resilience model, which is characterized by comprising the following steps as shown in fig. 1:
s1: and constructing a three-dimensional assembly model based on the geometric dimensions of the corrugated channel profile.
As shown in fig. 2, in step S1, the three-dimensional assembly model includes an upper roller 1, a lower roller 2, and a plate 3. Wherein the upper roller 1 is a male die, the lower roller 2 is a female die, and the two structures are mutually matched. The plate 3 is placed between the gaps of the upper roller 1 and the lower roller 2, and is formed by cold bending and rolling in the actual production process of the corrugated groove profile. Specifically, the cold roll forming in the actual production process of the aluminum alloy thin-wall corrugated groove profile is simulated, the plate 3 is an aluminum alloy plate, and the three-dimensional assembly model comprises 13 passes in total, namely 13 upper rollers 1 and 13 lower rollers 2 (only 3 passes are shown in fig. 2, and other parts which are not shown are the same as the 3 passes). The aluminum alloy plate is formed by rolling an upper roller 1 and a lower roller 2 to form the aluminum alloy thin-wall corrugated groove profile. In fig. 2, in order to form a six-grooved aluminum alloy thin-walled corrugated grooved profile, the upper roller 1 is constructed with seven male teeth and the lower roller 1 with seven female teeth.
S2: and (3) importing the three-dimensional assembly model into finite element software, and performing numerical simulation on the rolling forming and rebound processes of the corrugated groove type groove by using the finite element software.
Specifically, the finite element software adopts ABAQUS 2016 software, and the three-dimensional assembly model is imported into the finite element software in an x_t file. And carrying out numerical simulation on cold roll forming and rebound processes of the aluminum alloy thin-wall corrugated groove profile by finite element software. The rolling forming simulation analysis is consistent with the actual working condition, the upper roller and the lower roller are regarded as rigid bodies, the lower roller (female die) is regarded as a driving roller, the motor drives the upper roller (male die) to rotate clockwise, and then the friction force between the roller and the plate drives the upper roller (male die) to rotate. In particular numerical simulation, the plate 3 is 6061-T6 aluminum alloy plate with the width of 110mm and the thickness of 0.25mm, and other rolling process parameters are shown in the table 1 below.
S3: and establishing a simulation model in finite element software by adopting a dynamic-static combined algorithm, and predicting the resilience alpha of the corrugated groove profile.
Specifically, the finite element software adopts ABAQUS 2016 software, a dynamic-static combined algorithm is adopted to establish a simulation model, the rolling forming and rebound process of the corrugated groove profile is dynamically solved by display, and then the solved result is imported into an implicit algorithm to solve the rebound quantity of the corrugated groove profile. The springback of the aluminum alloy thin-wall corrugated groove profile rolled by cold bending often causes the defect of transverse bow, which is caused by uneven transverse springback of the corrugated groove profile, the springback amounts of the grooves are obviously different, and the defect can be seen in the simulation result, as shown in fig. 3. Fig. 3 shows the transverse bow defect of the profile caused by multi-groove rebound, and the aluminum alloy thin-wall corrugated groove profile is provided with six grooves, and the rebound quantity of the grooves at two sides is the largest. As shown in fig. 4, in order to better describe the rebound quantity α of the corrugated groove profile, the sum of the maximum rebound angles of the grooves at both sides is used as the basis for determining the rebound quantity, and the calculation is shown as follows:
α＝θ L +θ R (1)
wherein θ refers to the rebound angle; θ L Refers to the maximum rebound angle of the left groove; θ L Refers to the maximum rebound angle of the right side groove; Δz refers to the displacement difference between the two ends of the peak web in the Z-axis direction; Δy is the displacement difference at both ends of the peak web in the Y-axis direction. The example given in fig. 4 shows the rebound angle θ of the right side groove 1 ＞θ 2 The method comprises the steps of carrying out a first treatment on the surface of the Rebound angle θ of left groove 4 ＞θ 3 The method comprises the steps of carrying out a first treatment on the surface of the Thus θ R ＝θ 1 ，θ L ＝θ 4 ，α＝θ 1 +θ 4 。
TABLE 1
S4: and establishing a mathematical model of the rebound quantity alpha by utilizing linear regression analysis according to the rebound quantity alpha predicted in the step S3).
Specifically, linear regression analysis is carried out on the rebound quantity alpha fruit predicted in the step 3) based on Minitab software, and a mathematical model between the rebound quantity alpha and rolling process parameters is established. The formula of a specific mathematical model is as follows:
α＝22.34-0.5F.C-0.0465I.D-34.34R.G+5.992N-8.364B.A.C (3)
wherein, the influence degree evaluation results of the parameters are shown in Table 2, R 2 The = 98.51% (i.e. R-Sq, goodness of fit) indicates that the model fits well, and the model holds true. The T value reflects the positive and negative influence degree of each technological parameter on the rebound quantity. P is greater than 0.05, indicating that the effect of this parameter is negligible; otherwise, the influence of the description parameters is significant.
TABLE 2
If the fitting degree of the model is not high and the model establishment fails, repeating the steps S2-S4, setting more rolling process parameters, carrying out numerical simulation on the rolling forming and rebound process, and predicting the rebound quantity of the groove profile under each process parameter until a mathematical model with higher fitting degree and rebound quantity alpha is finally established, wherein the model establishment is successful.
And according to the evaluation result, adjusting the optimal technological parameters to carry out experimental study so as to control rebound after the thin-wall aluminum alloy corrugated groove profile is formed.
Based on the same inventive concept, in other embodiments, there is provided a wave groove profile resilience model predictive control system, the system comprising:
the three-dimensional model building module is used for building a three-dimensional assembly model based on the geometric dimension of the corrugated groove profile;
the numerical simulation module is used for performing numerical simulation on the rolling forming and rebound processes of the corrugated groove type groove;
the resilience amount prediction module is used for predicting the resilience amount of the corrugated groove profile in a simulation model established by adopting a dynamic-static combined algorithm;
and the rebound quantity mathematical model building module is used for building a rebound quantity mathematical model by utilizing linear regression analysis according to the predicted rebound quantity.
The modules in the above embodiment of the present invention may refer to the implementation technology of the steps corresponding to the method for predicting and controlling the resilience of the corrugated groove profile in the above embodiment, and will not be described herein.
By adopting the prediction control method and the prediction control system for the resilience quantity model of the corrugated groove profile, influence of each process parameter on the resilience quantity can be evaluated, so that the prediction and the control of the resilience of the corrugated groove profile are achieved. The rebound quantity of the corrugated groove profile is reduced to the minimum in a mode of optimizing the process parameters, the method is suitable for controlling the rebound quantity of the multi-groove rolling forming piece made of aluminum alloy and other alloy materials, the rolling forming quality of the corrugated groove profile is improved to a great extent, and the debugging cost of a rolling forming unit is greatly reduced.

Claims (11)

1. A method for predicting and controlling the rebound quantity of cold bending roll forming of corrugated groove profile comprises the following steps:
s1: constructing a three-dimensional assembly model based on the geometric dimensions of the corrugated channel profile;
s2: importing the three-dimensional assembly model into finite element software, and performing numerical simulation on the rolling forming and rebound processes of the corrugated groove type groove by using the finite element software;
s3: establishing a simulation model in finite element software by adopting a dynamic-static combined algorithm, and predicting the resilience of the corrugated groove profile;
s4: and establishing a mathematical model of the rebound quantity by utilizing linear regression analysis according to the rebound quantity predicted in the step S3).
2. The method of claim 1, further comprising s5 optimizing process parameters to minimize the amount of spring back.
3. The method according to claim 1, wherein in step S2, numerical simulation of the roll forming and rebound process of the corrugated-grooved is performed by setting roll process parameters in finite element software.
4. A method according to claim 3, wherein the roll process parameters include bend angle strategy, pass spacing, gap spacing, coefficient of friction and number of grooves formed.
5. The method of claim 1, wherein the three-dimensional assembly model comprises an upper roll, a lower roll, and a sheet material; the upper roller is a male die, the lower roller is a female die, the structures of the upper roller and the lower roller are mutually matched, and the plate is arranged between gaps of the upper roller and the lower roller.
6. The method according to claim 1, wherein in the step S3, the specific step of predicting the rebound amount of the corrugated channel profile comprises: and dynamically solving the rolling forming and rebound processes of the corrugated groove profile by utilizing the display, and then importing the solved result into an implicit algorithm to solve the rebound quantity of the corrugated groove profile.
7. The method according to claim 1, wherein in the step S3, the prediction of the rebound amount uses the following calculation formula:
α＝θ L +θ R (1)
wherein alpha refers to the rebound quantity; θ denotes the rebound angle; θ L Refers to the maximum rebound angle of the left groove; θ L Refers to the maximum rebound angle of the right side groove; Δz refers to the displacement difference between the two ends of the peak web in the Z-axis direction; Δy is the displacement difference at both ends of the peak web in the Y-axis direction.
8. The method according to claim 1, wherein in step S4, the mathematical model of the spring-back quantity relates to rolling process parameters including bending angle strategy, pass spacing, gap spacing, friction coefficient and number of forming grooves.
9. The method of claim 8, wherein the mathematical model of the rebound amount is formulated as follows:
α＝22.34-0.5F.C-0.0465I.D-34.34R.G+5.992N-8.364B.A.C (3)
wherein alpha refers to the rebound quantity; 22.34 refers to a constant; F.C means coefficient of friction; I.D refers to the pass interval; R.G the roll gap spacing; n refers to the number of forming grooves; a.c refers to the bend angle strategy.
10. A wave trough profile cold roll forming resilience prediction control system, characterized in that the system comprises:
the three-dimensional model building module is used for building a three-dimensional assembly model based on the geometric dimension of the corrugated groove profile;
the numerical simulation module is used for performing numerical simulation on the rolling forming and rebound processes of the corrugated groove type groove;
the resilience amount prediction module is used for predicting the resilience amount of the corrugated groove profile in a simulation model established by adopting a dynamic-static combined algorithm;
and the rebound quantity mathematical model building module is used for building a rebound quantity mathematical model by utilizing linear regression analysis according to the predicted rebound quantity.
11. A system according to claim 10, wherein,
the rolling forming and rebound process of the corrugated groove type groove is subjected to numerical simulation, a three-dimensional assembly model is required to be imported into finite element software in advance, and then the numerical simulation of the rolling forming and rebound process of the corrugated groove type groove is realized in the finite element software by setting rolling process parameters; the rolling process parameters comprise bending angle strategies, pass intervals, roll gap intervals, friction coefficients and the number of formed grooves;
the dynamic-static combined algorithm applies finite element software;
the three-dimensional assembly model comprises an upper roller, a lower roller and a plate; the upper roller is a male die, the lower roller is a female die, the structures of the upper roller and the lower roller are mutually matched, and the plate is arranged between gaps of the upper roller and the lower roller;
the prediction of the rebound quantity adopts the following calculation formula:
α＝θ L +θ R (1)
wherein alpha refers to the rebound quantity; θ denotes the rebound angle; θ L Refers to the maximum rebound angle of the left groove; θ L Refers to the maximum rebound angle of the right side groove; Δz refers to the displacement difference between the two ends of the peak web in the Z-axis direction; Δy is the displacement difference at both ends of the peak web in the Y-axis direction;
the mathematical model of the rebound involves rolling process parameters including bending angle strategy, pass spacing, roll gap spacing, coefficient of friction and number of formed grooves.
CN202310934787.8A 2023-07-27 2023-07-27 Method and system for predicting and controlling cold roll forming resilience of corrugated groove profile Pending CN116933426A (en)

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