Metal forming Modelling and Experiments

金属成形模拟与实验本研究方案的目标是通过对这种复杂的金属成形过程的实验和有效的数值模拟相结合，开发出一种用于难成形的高强度材料的高科技热辅助旋压工艺。板料旋压是将平板板材变形为中空形状的一种有效方法，通常具有轴对称的型材。该方法使用一种工具，即滚子，其将金属坯料强制到旋转心轴上。轧辊被压在坯料上，并沿轴向移动到复杂的轨迹中，最终得到中空形状的产品。为了以尽可能低的制造成本获得合适的形状，将进行实验来表征基础材料的特性。这些特性将用于建立该过程的有效有限元模型，包括加热策略，该策略首先将直接与轧辊位移联系在一起，然后将在位移中单独控制。通过真实的冷旋压和热旋压实验，将建立一个有价值的数据库，用于验证非线性动态有限元模拟。其目的是通过在难以成形的高强度材料的成形步骤中增加高科技热源(如激光加热)，使传统的旋压工艺达到一个新的技术水平，保持材料的性能和可接受的表面状态，并以尽可能低的成本维持热辅助旋压操作。

METAL FORMING MODELLING AND EXPERIMENTSThe objective of this research proposal is the development of a high tech heat assisted spinning process for hard-to-shape high strength materials through a combination of experiments and efficient numerical simulations of this complex metal forming process. Sheet-metal spinning is an effective method for transforming flat sheet metal into hollow shapes, usually with axisymmetric profiles. The method uses a tool i.e. a roller which forces a metal blank onto a revolving mandrel. The roller is pressed against the blank and is moved axially into complex trajectories to achieve finally a hollow-shaped product. To obtain the right shape at the lowest possible manufacturing cost, experiments will be conducted to characterize the base materials’ properties. These properties will be used to build an efficient finite element model of the process, including the heating strategy which will be first directly linked to the roller displacement and will be later separately controlled in displacement. Through real cold and hot spinning experiments a valuable database will be built and used for validation of non-linear dynamic finite element simulations. The goal is to bring the conventional spinning process to a new technological level by adding high tech heating sources (like laser heating) in the forming steps of hard to shape high strength materials, keeping material properties, acceptable surface state and maintaining the heat assisted spinning operation at the lowest cost as possible.