Metal forming Modelling and Experiments

金属成形建模和实验本研究提案的目的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，为难以成形的高强度材料开发一种高科技热辅助旋压工艺。金属板件旋压是一种将平板金属板件旋压成中空形状的有效方法，通常具有轴对称轮廓。该方法使用工具，即辊，其迫使金属坯料到旋转心轴上。辊压靠在坯料上，并轴向移动到复杂的轨迹中，以最终获得中空形状的产品。为了以尽可能低的制造成本获得正确的形状，将进行实验以表征基础材料的特性。这些特性将用于构建该过程的有效有限元模型，包括加热策略，该加热策略首先与辊位移直接相关，然后在位移中单独控制。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，并用于非线性动态有限元模拟的验证。其目标是通过在难以成形的高强度材料的成形步骤中添加高科技加热源（如激光加热），将传统的纺丝工艺提升到新的技术水平，保持材料性能、可接受的表面状态，并以尽可能低的成本维持热辅助纺丝操作。

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.