FEM dynamic simulation and analysis of the roll-bending process for forming a conical tube
FEM dynamic simulation and analysis of the roll-bending process for forming a conical tube
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DOI：
10.1016/j.jmatprotec.2007.07.016
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发表时间：
2008-03-03
影响因子：
6.3
通讯作者：
Champliaud, Henri
中科院分区：
文献类型：
--
作者：
Zeng, Jun;Liu, Zhaohenq;Champliaud, Henri
建立了一个通用的有限元仿真模型，用于研究辊板弯曲的动态过程。本文采用锥形辊连续三辊锥形弯曲装置将厚板弯曲成锥形板状。介绍了轧辊与工件之间的运动关系、几何设置和有限元模型。在模拟过程中，可以可视化从初始板到最终圆锥形状的动态成形过程，以及工件随时间的应力变化。在ANSYS/LS-DYNA环境下，采用弹塑性显式动力有限元法进行三维模拟。还开发了一种数值算法，以量化所产生的圆锥形状相对于所需的截头圆锥的尺寸和几何精度。Levenberg-Marquardt非线性算法在此步骤中实现，将FE软件生成的点云拟合到最小二乘圆锥中，用于与理想圆锥进行比较。参数研究进行调查的各种参数，包括摩擦系数，对最终形状的质量的影响，根据模拟结果。说明了所需的力和扭矩方面的板厚和辊配置。本文旨在研究厚板辊弯成形工艺的可行性，并为工程技术人员提供一种方便的数值工具来优化工艺参数。(C)2007 Elsevier B. V.保留所有权利。
A general simulation model is developed to study the dynamic process of roll plate bending using finite element method (FEM). In this work, the continuous three-roll pyramidal bending configuration with conical rolls is used to bend a thick plate into a conical tabular shape. We present the kinematic relationship existing between rolls and workpieces, the geometrical setup and the finite element model. The dynamic forming process, going from the initial plate to the finished conical shape, as well as the stress variation of the workpiece over time, can be visualized during the course of the simulation. This 3D simulation is based on the elastic-plastic explicit dynamic finite element method under the ANSYS/LS-DYNA environment. A numerical algorithm is also developed to quantify the dimensional and geometrical accuracy of the produced conical shape with respect to the desired truncated cone. The Levenberg-Marquardt nonlinear algorithm is implemented in this step in fitting the point clouds generated by the FE software into a least-square cone, which is used for comparison with an ideal one. Parametric studies are carried out to investigate the effects of various parameters, including friction coefficient, on the quality of the final shape, based on simulation results. The required forces and torques in terms of plate thickness and roll configurations are illustrated. This work is conducted in an attempt to study the feasibility of using the roll-bending process with thick plates and to provide engineers with a convenient numerical tool for optimizing process parameters. (C) 2007 Elsevier B.V. All rights reserved.