JP4231426B2 - Metal material molding simulation method - Google Patents

Description

  The present invention predicts a press failure with high accuracy by a finite element method simulation at a press die design stage in a process of manufacturing a part such as an automobile part by press forming using a metal plate. The present invention relates to a friction coefficient calculation method that reduces the manufacturing cost by shortening the die manufacturing delivery time and further reduces the rate of occurrence of press defects, and a molding simulation method by a finite element method that takes into consideration a nonlinear friction model using the friction coefficient calculation method.

  In the conventional finite element method simulation, the Coulomb friction law which treats the friction coefficient as a constant is used. For this reason, changes in the coefficient of friction during molding are not taken into account in the numerical analysis simulation. Forming simulation by the finite element method inputs the mechanical properties of the material as a material constitutive equation, and solves the balance equation of the deformation state of the material by inputting the friction coefficient for the contact problem with the tool (static implicit method). Or a static explicit method) or a dynamic equation (dynamic explicit method) to output a stress distribution or a strain distribution. However, since the conventional finite element method program does not accurately reflect the change of the friction coefficient, it is impossible to output an accurate stress distribution or strain distribution, and it cannot be said that the predictability of molding is sufficient.

  In addition, as an example in which the friction coefficient is treated as a state function and the nonlinear friction model is incorporated into the finite element method, Non-Patent Document 1 is a state in which polynomial approximation is performed using two parameters, sliding distance and strain applied to a non-working material. A function is described, and Non-Patent Document 2 describes a state function obtained by approximating a polynomial function with two parameters of surface pressure and friction work.

  However, the accuracy of numerical analysis by the finite element method is not sufficient even with these methods.

Nakamachi et al. (1992 Spring Processing Seminar, (1992), P355) Hashimoto et al. (Plasticity and processing, Vol.44, No.504, (2003), P35)

  It is an object of the present invention to provide a metal material forming simulation method capable of further improving analysis accuracy in carrying out a metal material forming simulation in which a friction coefficient changes during forming processing of a surface-treated steel sheet or the like. To do.

  As a result of intensive studies, the present inventors have focused on the friction coefficient that changes during the molding process due to various pressing conditions in the above Non-Patent Documents 1 and 2, and 2 of various factors that affect the change of the friction coefficient. Whereas only one is taken into account, by using the state function display of the coefficient of friction by a polynomial equation with the state variable being analyzed, a nonlinear friction model is incorporated into the finite element method program, and the friction change during the molding process is incorporated. We developed a finite element method simulation program that can output accurate stress distribution and strain distribution by minimizing the error of numerical analysis.

Specifically, in the present invention, the friction coefficient of the metal plate is obtained by a polynomial approximation formula using the surface pressure, the friction work, and the plastic strain. For example, the friction coefficient rather than treated as a constant value as Coulomb law, the friction coefficient _{μ (P N, ω, ε} P) as the surface pressure (P _N [Pa]) and friction work amount (omega [ N / m]) and the plastic strain (ε _P ), the friction coefficient μ of the metal plate is calculated by a polynomial approximation formula.

  As the metal plate, for example, a coefficient of friction is obtained by selecting one type selected from the group consisting of mild steel plate, high-tensile steel plate, surface-treated steel plate, lubricated steel plate, stainless steel plate, and stainless steel plate and clad steel plate. Can be targeted.

  Further, the metal material forming simulation method according to the present invention is characterized in that a friction coefficient of the metal plate is obtained by any one of the above methods, and a forming simulation by a finite element method is performed using the friction coefficient of the metal plate. And

  According to the present invention, the numerical analysis simulation accuracy of press forming by the finite element method can be remarkably improved. Therefore, it can be said that the present invention is an industrially extremely valuable invention.

A finite element method simulation program considering a nonlinear friction model according to an embodiment of the present invention is a method for preliminarily determining a friction coefficient μ of a metal plate by a polynomial approximation expression using various parameters according to a workpiece and press forming conditions. To the algorithm. Depending on the conditions, a polynomial approximate expression expressed using not only the surface pressure: P _N and the friction work: ω but also the plastic strain: ε _P as the friction coefficient μ (P _N , ω, ε _P ). Apply as a function.

  Factors affecting the coefficient of friction can be broadly classified into those caused by molding conditions and those caused by changes in the material during the molding process.

Typical factors that affect the coefficient of friction due to the molding conditions include the molding speed S when the metal plate is molded by a mechanical press, hydraulic press, transfer press, AC servo control press, etc., on the die face, localized surface pressure P _N of differences material undergoes the die shoulder and the bead portion or the like, change in pressure holding wrinkles due to the variable blank holding pressure control, etc., the influence of the viscosity υ by type of difference in the lubricating oil, and the mold material Examples thereof include _a hardness difference ΔH with respect to the workpiece and a roughness Ra.

In addition, factors affecting the coefficient of friction due to changes that occur in the material during the molding process include changes in the surface topology of the workpiece as the sliding distance increases between the workpiece and the mold, Examples thereof include heat effects due to processing heat generation and sliding heat generation, and plastic strain ε _P generated while the workpiece is subjected to plastic deformation.

Of these factors, the friction work expressed by the sum of products of the friction resistance pressure ΔP _Tn [Pa] and the sliding distance ΔS _Ln [m] received during a certain time Δt _n of a specific part of the workpiece. The quantity ω (= ΣΔP _T · ΔS _L ) [N / m] plays a very important role as a parameter representing the surface topology change of the workpiece. Experiments have shown that if the change is at the same level, the same coefficient of friction is given in the next slide. Further, it was also found from detailed experiments that the surface pressure _PN has a great influence on the coefficient of friction in subsequent sliding in samples having the same surface topology. Therefore, it is essential to apply the friction work ω and the surface pressure P _N to state variables when the friction coefficient is expressed by a state function.

  However, even if these two parameters are adopted as state variables, the change in the coefficient of friction cannot be fully expressed in the combination of molding conditions and workpieces, and it is difficult to perform highly accurate numerical analysis simulations. .

Therefore, as a result of repeated studies by the inventor, the plastic strain ε _P is incorporated into the polynomial approximation formula as a new parameter among the factors that change during the molding process of the friction coefficient listed above, and the state of the friction coefficient It has been found that the accuracy of the finite element method simulation is remarkably improved by using it as a function. It has been found that the plastic strain generated in the workpiece during forming causes cracks on the surface in the case of a plated steel sheet, which also affects the coefficient of friction.

Therefore, a state function μ (P _N , ω, ε _P ) representing a friction coefficient may be determined as a state variable by a combination of molding conditions and a workpiece.

  And, according to such a calculation method of the friction coefficient, the processing conditions such as a change in forming speed and wrinkle holding pressure when the metal plate is formed by a mechanical press, a hydraulic press, a transfer press, an AC servo control press, etc. Changes in the friction coefficient due to changes in the surface topology of the workpiece as the sliding distance between the workpiece and the mold increases, are considered in the forming simulation using the finite element method. As a result, numerical analysis accuracy can be improved.

Here, the material used as the metal plate is, for example, a mild steel plate, a high-tensile steel plate, a steel material such as a surface-treated steel plate, a lubricated steel plate, or a stainless steel plate, or a clad steel plate such as a stainless steel plate / steel plate. The aluminum plate, the aluminum alloy plate, the titanium plate, and the titanium alloy plate are not suitable for molding with a long sliding distance because of galling with the mold, and the friction work ω and the surface pressure P _In addition to _N , it is difficult to represent a feature even with a friction coefficient display using one or more parameters as state variables.

In addition, as a friction coefficient test method for obtaining various parameters using various factors as state functions, a general friction coefficient test method such as a Bowden test method or a flat plate pull-out test method, or a continuous sliding test machine proposed by the present inventor is used. (Plasticity and processing, Vol. 44, No. 504, (2003), P35), etc., the frictional work ω is obtained by variously changing the surface pressure _PN and sliding the same portion multiple times. Further, the friction coefficient is measured under conditions where three or more parameters are varied by variously changing the sliding speed S, tool hardness H, metal plate roughness _Ra , and lubricating oil viscosity υ as other parameters. Each coefficient of the state function of the friction coefficient expressed by a polynomial using various parameters is specified by calculation such as the least square method based on the results of many experiments thus obtained, and the state of the friction coefficient expressed by polynomial approximation It can be calculated as a function.

  Further, the friction coefficient calculated by the above method in the forming simulation by the finite element method with the friction coefficient introduced can be input as a parameter and used for the calculation. As the molding simulation, a known dynamic explicit FEM (Pam-stamp, LS-DYNA, etc.), static explicit FEM (ITAS-3D, etc.), static implicit FEM (ABAQUS, AUTOFORM, etc.) can be used. .

  Next, a forming simulation method based on the finite element method in consideration of the nonlinear friction model according to the present invention will be described in detail on the basis of an actually performed example.

A molding simulation of a cylindrical deep drawing test of a 300 mm diameter punch was carried out by a dynamic explicit FEM program incorporating a nonlinear friction model expressed by polynomial approximation with a factor affecting the friction coefficient as a parameter. A 0.8 mm thick galvannealed steel sheet (GA) was used as a molded sample. Here, in the calculation, the Coulomb friction law with a constant friction coefficient is used in Comparative Example 1, and in Comparative Example 2, only two of surface pressure P _N [Pa] and friction work ω [N / m] are used as state variables. In the embodiment of the present invention, the surface pressure P _N [Pa] and the friction work ω [N / m] are used as the state variables in the embodiment of the present invention using the friction coefficient state function μ (P _N , ω) of the nonlinear friction model using In addition, the state function μ (P _N , ω, ε _P ) of the friction coefficient of the nonlinear friction model using the plastic strain ε _P was used.

The friction work ω [N / m] is given by Equation 1. Here, P _T represents the tangential frictional resistance pressure [Pa], and g _sl represents the sliding distance [m].

Regarding Comparative Example 2, the state function μ (P _N , ω) of the friction coefficient of the nonlinear friction model using only two of P _N given by the surface pressure and ω given by the friction work as state variables is The number is 2.

However, in Equation 2, each coefficient is obtained by the method of least squares. In the case of an electrogalvanized steel sheet, A ₀ = 0.166, A ₁ = −0.252 × 10 ⁻⁵ , A ₂ = −0.219 × 10 ⁻⁶ , A ₃ = 0.293 × 10 ⁻¹¹ , A ₄ = 0.244 × 10 ⁻¹⁰ , A ₅ = 0.895 × 10 ⁻¹² , A ₆ = 0.373 × 10 ⁻¹⁶ , A ₇ = 0.315 × 10 ⁻¹⁸ , A ₈ = −0.165 × 10 ⁻¹⁵ , and A ₉ = −0.113 × 10 ⁻¹⁷ .

Further, regarding the embodiment of the present invention, the state function of the friction coefficient of the nonlinear friction model using three of the surface pressure P _N [Pa], the friction work ω [N / m], and the plastic strain ε _P as the state variables. μ (P _N , ω, ε _P ) was set to Equation 3.

However, in Equation 3, each coefficient is obtained by the method of least squares. In the case of an electrogalvanized steel sheet, A ₀ = 0.273, A ₁ = −0.141 × 10 ⁻⁶ , A ₂ = −0.105 × 10 ⁻⁷ , A ₃ = 0.536 × 10 ⁻⁸ , A ₄ = 0.185 × 10 ⁻¹⁵ , A ₅ = 0.212 × 10 ⁻⁹ , A ₆ = −0.184 × 10 ⁻²⁰ , A ₇ = 0.306 × 10 ⁻¹¹ , A ₈ = −0.243 × 10 ⁻¹⁹ , A ₉ = −0.124 × 10 ⁻¹⁸ , and A ₁₀ = 0.256 × 10 ⁻⁸ .

  The notation of the state function is not limited to these.

  FIG. 1 shows an analysis result (plate thickness distribution) using a nonlinear friction model according to an embodiment of the present invention under a molding condition of a wrinkle holding pressure of 240 kN as an example of the molding analysis result. FIG. 2 shows the experimental results of the molding height when the wrinkle holding pressure is three conditions of 240 kN, 480 kN, and 720 kN, and the molding height at the time when it is determined that the fracture is 25% or more and the fracture is determined by analysis. Shown in comparison.

  As shown in FIG. 2, in Comparative Example 1 (Coulomb friction law with a constant friction coefficient), when the wrinkle holding pressure was 480 kN and 720 kN, the molding height was lower than the experimental result. In Comparative Example 2 (nonlinear friction model using two state variables), simulation results close to the experimental results are obtained in the case of wrinkle holding pressures of 240 kN and 720 kN, but with wrinkle holding pressure of 480 kN, The accuracy of the molding simulation is not sufficient.

  In contrast to these comparative examples, in the examples of the present invention, simulation results almost identical to the experimental results were obtained.

In Example 2, a rear member forming simulation was performed with a dynamic explicit FEM program in which the state function μ (P _N , ω, ε _P ) of Example 1 was incorporated into the program as a nonlinear friction model. As a forming sample here, an electrogalvanized steel sheet (EG) having a thickness of 0.8 mm was used.

  FIG. 3 shows the plate thickness distribution when the forming analysis is performed under the condition of the wrinkle holding pressure of 400 kN as an example of the forming analysis result. As in the case of a general fracture determination method, when a state in which the plate thickness is reduced by 25% or more with respect to the original plate thickness is determined to be a break, as shown in FIG. Can be distinguished. “Forming available zone” in FIG. 4 is a formable range obtained by actual measurement, and the upper limit is about 400 kN.

  In the comparative example (Coulomb friction model with a constant friction coefficient), the plate thickness reduction due to press forming has been overestimated, so the reduction rate is 25% at any of the wrinkle holding pressures of 300 kN, 400 kN and 600 kN. The result was that there was no moldable range. That is, the difference from the moldable range obtained by actual measurement was extremely large.

  On the other hand, in the embodiment of the present invention (non-linear friction model in which the friction coefficient is expressed as a state function using three factors as parameters), it is in very good agreement with the formable range (400 kN or less) obtained by actual measurement. The result which shows was obtained.

It is a figure which shows the numerical simulation result by the Example of this invention. It is a graph which shows the cylindrical deep drawing molding height of the Example and comparative example of this invention. It is a figure which shows the other numerical simulation result by the Example of this invention. It is a graph which shows the wrinkle pressing pressure range which can be deep-drawn by an example of the present invention and a comparative example.

Claims (2)

  A metal material characterized by obtaining a friction coefficient of a metal plate by a polynomial approximation formula using a surface pressure, a friction work, and plastic strain, and performing a forming simulation by a finite element method using the friction coefficient of the metal plate Molding simulation method.   The metal plate is one type selected from the group consisting of mild steel plates, high-tensile steel plates, surface-treated steel plates, lubricated steel plates, stainless steel plates, and stainless steel plates and clad steel plates. The metal material forming simulation method according to claim 1.

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