Metal forming Modelling and Experiments

金属成形建模和实验本研究计划的目标是通过结合实验和有效的数值模拟这一复杂的金属成形过程，开发一种用于难成型高强度材料的高科技热辅助纺丝工艺。金属薄板旋压是一种将平面金属薄板加工成中空形状的有效方法，通常具有轴对称的外形。该方法使用一种工具，即一个滚轮，它将金属毛坯压在旋转的芯轴上。将滚轮压在坯料上，并沿复杂轨迹轴向移动，最终得到空心产品。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材的性能。这些特性将用于建立有效的过程有限元模型，包括加热策略，加热策略将首先直接与滚轮位移相关联，然后在位移中单独控制。通过实际的冷、热旋压实验，将建立一个有价值的数据库，并用于验证非线性动态有限元模拟。目标是通过在难成型高强度材料的成型步骤中加入高科技热源（如激光加热），保持材料性能和可接受的表面状态，以尽可能低的成本保持热辅助纺丝操作，将传统纺丝工艺提升到一个新的技术水平。

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.