基于磁-热-固全耦合和双重网格技术的感应加热弯板成形预测方法研究

海洋强国战略的实施迫切需要实现高新技术船舶感应加热弯板成形的智能化和自动化。但现有大尺寸船板成形高精度预测方法计算耗时，且其等效热源构建过度依赖经验假设，难以满足智能制造中建立固有变形数据库和变形预报系统的需要。为提高感应加热弯板成形预测能力，本项目综合运用电磁感应理论、多物理场耦合分析和试验，开展感生热源分布影响机理和双重网格热弹塑性优化计算方法研究，主要研究内容：(1)基于网格随移方法，建立考虑加热变形的磁-热-固全耦合模型；(2)探讨感应器形状、温度变化和加热变形对感生热源分布的影响规律，精确构建考虑感应器-温度-加热变形的感生热源等效模型；(3)建立分别用于计算和存储数据的双重网格，探讨双重网格映射算法和数据传递频次对计算精度和效率的影响。完成以上基础研究，建立感应器-温度-加热变形的双重网格热弹塑性计算方法，提高感应加热弯板成形现场计算能力，为弯板成形智能化和自动化提供科学支持。

The implementation of the strategy of ocean power needs urgently to realize the intelligence and automation of plate bending with induction heating for high-tech ship. However, the existing high-precision prediction methods for large-sized plate bending have low efficiency and excessive reliance on empirical assumptions for the construction of equivalent heat sources. Therefore, it is difficult to meet the needs of the construction of inherent deformation database and technical parameters prediction system in intelligent manufacturing. In order to improve the calculation ability of plate bending with induction heating, the influence mechanism of induced heat source distribution and dual-mesh thermal elastic-plastic method are studied based on electromagnetic induction theory, multi-physics coupling analysis and experiment. The main research contents are: (1) Based on the mesh morphing method, the magnetic-thermal-structural fully coupling model is established to consider heating deformation; (2) The influence of inductor shape, temperature change, and heating deformation on the distribution of induced heat source is clarified, and the equivalent model of induced heat source that takes into account inductor-temperature-heating deformation is accurately built; (3) The dual-mesh for calculation and storing data is established, and the effects of mapping algorithm and data transfer frequency between the dual-mesh on the accuracy and efficiency of calculation are researched. Through the above studies, a dual-mesh thermal elastic-plastic model considering the inductor-temperature-heating deformation will be established, and the calculation capability of factory on-site for induction plate bending will be improved. And so, it can provide scientific support for the intelligence and automation of plate bending with induction heating.