CN106709148A - Finite element simulation method for roll bending-milling process of large-scale stepped thin-walled workpiece - Google Patents
Finite element simulation method for roll bending-milling process of large-scale stepped thin-walled workpiece Download PDFInfo
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- CN106709148A CN106709148A CN201611051217.0A CN201611051217A CN106709148A CN 106709148 A CN106709148 A CN 106709148A CN 201611051217 A CN201611051217 A CN 201611051217A CN 106709148 A CN106709148 A CN 106709148A
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- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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Abstract
The invention discloses a finite element simulation method for a roll bending-milling process of a large-scale stepped thin-walled workpiece. The method comprises the following steps of: establishing a roll bending model of a plate material which is an elastic plastic body, and carrying out grid generation by adoption of shell units so as to simulate a roll bending process of the plate material; simulating a side scraping process through a sub-model technology, segmenting a to-be-milled area of the plate material according to a part structure of the large-scale stepped thin-walled workpiece, and modifying thickness values of shell units in different areas of the plate material so as to simulate a milling process of the large-scale stepped thin-walled workpiece; and simulating a spring-back process. According to the finite element simulation method for the roll bending-milling process of the large-scale stepped thin-walled workpiece, the roll bending-milling process of the large-scale stepped thin-walled workpiece can be accurately controlled, and the spring-back in the machining process can be controlled and even eliminated, so that the defect that the material performance is reduced due to the usually adopted means such as later shape correction, repeated roll bending and the like is avoided.
Description
Technical field
The present invention relates to be machined and Forming Simulation field, more particularly to roll bending-milling of the large scale with step thin-wall part
Cut the finite element simulation method of process.
Background technology
In order to meet safety, economic, comfortable, environmental protection composite request, new commercial aircraft is in organism material and structure
It is on the other hand a large amount of to use on the one hand from aluminium alloy, the light material that aluminium lithium alloy isodensity is small, specific strength is high in selection
Multi-step thin-wall construction, such as head, middle rear body covering, by skinpiston local reduction, forming multi-step thin-walled knot
Structure, can make skinpiston weight saving more than 40%.Wherein, single-curvature is the typical case of aircraft skin wallboard with step thin-wall structure
Light structures form, by roll forming single-curvature large size plate, and carry out Milling Process obtain single-curvature band step thin-wall
Structural member.
Roll bending is, using two to four roll shafts of synchronous rotary, sheet material is produced continuous plastic bending and by controlling roll shaft
Spacing realizes the manufacturing process of curvature needed for part, is widely used in the manufacture of sheet metal part.In Aircraft Production,
Roll bending technique is mainly used in shaping fuselage, wing cover, the single-curvature part such as fuel tank exterior skin, shape it is latter as will be by chemistry
Milling or mechanical milling remove excess stock and reach topology requirement and loss of weight purpose.Stressed-skin construction part is pneumatic outer composition aircraft
The strength member of shape, undertakes the effect for bearing and transmitting load, thus form accuracy requirement is very high.But in roll bending process, plate
The final curvature of material is influenceed by material self performance, friction, resilience etc. are multifactor, and accurate size control is relatively difficult, special
Be not large-scale part roll bending process in, its rebound phenomenon is even more serious.Simultaneously in chemistry milling or mechanical milling process
Because the influence of the factors such as milling shape, depth can cause further resilience, the part accuracy of manufacture is further increased
The difficulty of control, dimensional accuracy and production efficiency to part cause strong influence.
In actual production, typically resilience is controlled or disappeared by means such as later stage school shape or multiple roll bendings
Remove.However, these operations can cause the reduction of material property, thus precise control covering roll bending-milling process resilience to working as
Preceding aircraft large scale stressed-skin construction part is formed with significance.Realize that covering roll bending-milling is returned using traditional " trial-and-error method "
The control of bullet needs substantial amounts of checking test, while precision is also difficult to ensure.And can using finite element simulation research bending forming
More comprehensively to analyze influence of each factor of roll bending process to machining accuracy, but finite element simulation technology is in roll bending and milling
Application and research on the integrated emulation of journey is also in blank.Therefore, need a kind of large scale band step thin-wall part that is applied to badly rolling
The finite element simulation method of curved-milling overall process being manufacturing and designing with step thin-wall part, such as design of aircraft skin part
Manufacture, there is provided simulation analysis and the effective means of theoretical research, so that roll bending-milling of the precise control large scale with step thin-wall part
Process is cut, the resilience in process is controlled or eliminated, with the later stage school shape or many for avoiding generally using at present
The reduction of the material property caused by the means such as secondary roll bending.
The content of the invention
The technical problem to be solved in the present invention is to overcome in the prior art by later stage school shape or multiple roll bending etc.
Resilience of the means to large scale in the roll bending-milling process with step thin-wall part is controlled, and can cause the material of thin-wall part
The defect that can be reduced, proposes a kind of finite element simulation method of roll bending-milling process of the large scale with step thin-wall part.
The present invention is to solve above-mentioned technical problem by following technical proposals：
A kind of finite element simulation method of the roll bending-milling process with step thin-wall part the invention provides large scale, its
Feature is that the finite element simulation method is comprised the following steps：
Step one, the roll bending model for setting up plate, the plate are elasticoplastic body, and integrate shell unit using linear decrement
Mesh generation is carried out, the roll bending model is used to simulate the roll bending process of plate, and the roll bending process includes the bending of plate, rolling
Curved and resilience；
Step 2, based on the result after roll bending process described in the roll bending modeling, simulated by Sub-model Technology and cut
Crack approach, wherein trimming process remove the edge straight portion of plate and retain middle homogeneous deformation region, then according to institute
That states that design of part of the large scale with step thin-wall part be partitioned into plate treats milling region, and changes the shell of the different zones of plate
The thickness value of unit, to simulate milling process of the large scale with step thin-wall part；
Step 3, the workpiece obtained based on step 2 simulation milling process, carry out the simulation of springback process, springback process
Simulation includes closing vacuum suction system, and the workpiece for obtaining milling is in without constraint free deformation on vacuum platform,
It is in criss-cross five points to select the center of plate in the bottom surface of the workpiece, constrain five points displacement and rotate with
The springback calculation after plate milling is carried out, wherein be that central point is completely fixed to the constraints of five points, and other
Four points are then confined to reduce the influence to resilience to greatest extent.
It is preferred that being to the constraints of other four points in five points in addition to central point：
With respect to central point with first axially distribution 2 points, the translation freedoms of its second axial direction and around first axially and
Rotary freedom around the 3rd axial direction suffers restraints；
With respect to central point with second axially distribution 2 points, the translation freedoms of its first axial direction and around second axially and
Rotary freedom around the 3rd axial direction suffers restraints；
Wherein first axial direction, the second axial direction, the 3rd are axially mutually perpendicular to, and second is axially the direction of plate roll bending.
It is preferred that in step one, modeling upper roller, two bottom rolls using discrete rigid body and being connect as with plate
Touch the part of extruding, and according to large scale the roll forming process control roller with step thin-wall part motion, simulate roll bending
Process.
It is preferred that the simulation of the roll bending process includes three below analysis step：
The first step, the upper roller is pushed to cause sheet metal bending, is realized to roll bending by the volume under pressure of the upper roller of adjustment
The control of the bending radius of process；
Second step, the upper roller keeps pressed status constant and rotation, and plate is realized by the CONTACT WITH FRICTION with plate
Roll bending, the bottom roll be servo-actuated so that plate roll bending by a lateral edges, the upper roller after roll bending to another lateral edges
Reversion, the original position for returning to pressed status stops；
3rd step, roll bending terminates, the upper roller lifting, and plate occurs resilience.
It is preferred that in step one, opening the enhancing control of hourglass rigidity and hourglass occur with plate in avoiding the roll bending process.
It is preferred that the finite element simulation method uses ABAQUS software implementations.
It is preferred that the calculating in step one is calculated using explicit algorithm Explicit.
It is preferred that simulating springback process using Static implicit algorithm in step 3.
It is preferred that the large scale band step thin-wall part is single-curvature band step thin-wall part.
On the basis of common sense in the field is met, above-mentioned each optimum condition can be combined, and obtain final product each preferable reality of the present invention
Example.
Positive effect of the invention is：
The finite element simulation method of roll bending-milling process of the large scale of the invention with step thin-wall part, can accurately control
Roll bending-milling process of the large scale processed with step thin-wall part, can control even to eliminate the resilience in process, it is to avoid mesh
The defect of the material property reduction caused by the means such as the later stage school shape of preceding usual use or multiple roll bending.
Brief description of the drawings
Fig. 1 is that the finite element of roll bending-milling process of the large scale of a preferred embodiment of the present invention with step thin-wall part is imitated
The flow chart of true method；
Fig. 2 be a preferred embodiment of the present invention finite element simulation method in the original state of roll bending model of plate show
It is intended to；
Fig. 3 is the schematic diagram of the hourglass problem being likely to occur in finite element simulation；
During Fig. 4 is the finite element simulation method of a preferred embodiment of the present invention, the part after plate milling, trimming is illustrated
Figure；
During Fig. 5 is the finite element simulation method of a preferred embodiment of the present invention, 5 points of signals of constraint of resilience after milling
Figure；
Specific embodiment
With reference to Figure of description, further the preferred embodiments of the present invention are described in detail, description below
For exemplary, not limitation of the present invention, other any similar situations are still fallen among protection scope of the present invention.
In following specific descriptions, the term of directionality, such as "left", "right", " on ", D score, "front", "rear", etc.,
Direction described in refer to the attached drawing uses.The part of embodiments of the invention can be placed in various different directions, directionality
Term is for illustrative purposes and nonrestrictive.
With reference to shown in Fig. 1, the roll bending-milling process of the large scale with step thin-wall part of a preferred embodiment of the present invention has
The first emulation mode of limit, comprises the following steps：
Step one, the roll bending model for setting up plate, the plate are elasticoplastic body, and integrate shell unit using linear decrement
Mesh generation is carried out, the roll bending model is used to simulate the roll bending process of plate, and the roll bending process includes the bending of plate, rolling
Curved and resilience；
Step 2, based on the result after roll bending process described in the roll bending modeling, simulated by Sub-model Technology and cut
Crack approach, wherein trimming process remove the edge straight portion of plate and retain middle homogeneous deformation region, then according to institute
That states that design of part of the large scale with step thin-wall part be partitioned into plate treats milling region, and changes the shell of the different zones of plate
The thickness value of unit, to simulate milling process of the large scale with step thin-wall part；
Step 3, the workpiece obtained based on step 2 simulation milling process, carry out the simulation of springback process, springback process
Simulation includes closing vacuum suction system, and the workpiece for obtaining milling is in without constraint free deformation on vacuum platform,
It is in criss-cross five points to select the center of plate in the bottom surface of the workpiece, constrain five points displacement and rotate with
The springback calculation after plate milling is carried out, wherein be that central point is completely fixed to the constraints of five points, and other
Four points are then confined to reduce the influence to resilience to greatest extent.
It should be appreciated that the resilience being related in the resilience of the plate being related in step one and step 3 is part rolling
The different resilience successively occurred in the process of curved-milling process.Preceding is once the resilience in roll bending process, after once then
It is to be typically due to during milling, milling be influenceed the further resilience that causes by factors such as milling depth, shapes.
The accuracy of finite element simulation and the foundation of FEM model and boundary condition for part process are really
It is vertical to have direct relation, it is to be understood by those skilled in the art that boundary condition typically all can attempt mould by finite element simulation
Specific processing request, accessory size of part process of plan etc. determine, will not be described here.It is big for of the present invention
Roll bending-milling process of the size with step thin-wall part, roll bending and milling are two important procedures of forming process, so roll bending mould
Type and Data Model are the important component in technical solution of the present invention, the foundation of the two models and the correlation for being carried out
Simulation, computing generally may correspond to step one of the invention and step 2.To below illustrate in more detail of the invention
The finite element simulation method of roll bending-milling process of the large scale with step thin-wall part.
In the preferred embodiment, above-mentioned steps one specifically may include following process.For example, with reference to Fig. 2
It is shown, model can be set up according to the structure and size of three axillare material roll bending machines, in model have three rollers as with plate
3 critical pieces for coming in contact and extruding, three rollers are modeled using discrete rigid body, do not consider that it deforms.Used in modeling
Parameter includes the radius r1, two radius r2 of bottom roll 2, the spacing L of bottom roll 2 of upper roller 1.Plate 3 is modeled as elastoplasticity
Body, and mesh generation is carried out from linear decrement integration shell unit S4R, and the enhancing control of hourglass rigidity is opened, prevent roll bending mistake
There is hourglass in plate in journey.The hourglass defect being likely to occur is shown in Figure 3.Plate is placed between up-down roller, according to roll bending
The real process of shaping controls the motion of roller, realizes roll bending process.
Specifically, roll bending process can complete emulation by setting up three below analysis step：The first step, under upper roller 1
Pressure so that plate 3 bends, can realize bending half to roll bending process by the volume under pressure H (as shown in Figure 2) of the upper roller 1 of adjustment
The control in footpath；Second step, upper roller 1 keeps pressed status motionless, and the rotation of upper roller 1 is realized by the CONTACT WITH FRICTION with plate 3
The roll bending of plate 3, bottom roll 2 is servo-actuated, the roll bending by a lateral edges of plate 3, and upper roller 1 is anti-after roll bending to another lateral edges
Turn, return to the original position for pushing and stop；3rd step, after roll bending terminates, upper roller 1 rises, and plate 3 occurs resilience.Roll bending mistake
The specific calculating and simulation of journey, can be calculated using the explicit algorithm Explicit of such as ABAQUS softwares.
In the preferred embodiment, the emulation of trimming, the milling of local submodel is completed using above-mentioned steps two.
Wallboard after milling is as shown in figure 4, step 2 specifically may include following process.
In Milling Simultion Models, because its simulation process is the simulation result based on roll bending, therefore Milling Simultion Models,
Only need to individually set up the FEM model of blank.Physical dimension based on submodel feature and milled part, to blank
Size is redefined, and makes it consistent with the accessory size after trimming；Plate is split simultaneously, it would be desirable to the region of milling point
Cut out, its thickness is redefined, make it consistent with the thickness distribution after the actual milling of blank.Finally, by submodule
Type is reruned technology, and the simulation result of roll bending model is realized into submodel is reruned in the plate after restructuring, and is completed roll bending and is imitated
The transmission of true result, realizes the emulation of milling process.
By above-mentioned steps, the member-retaining portion of the plate after trimming will be simulated as local submodel, modification corresponds to band
The thickness value of the shell unit of the different zones of step thin-wall structure to simulate milling process, after obtaining simulating the milling for obtaining
The simulation result of part.
In the preferred embodiment, the resilience using the simulation part material of above-mentioned steps three after milling.Specifically
For, based on the RAP material result in step 2, by way of predefined field RAP material result is delivered into resilience imitates
In true mode.The redistribution of blank internal stress is only related to due to blank springback process, therefore resilience simulation model need to only be built
Vertical blank model, based on predefined field and resilience feature, the size of blank should be with RAP material with structure in resilience simulation model
Billet size in model is consistent.Springback process in step 3 completes simulation using Static implicit algorithm.
The selection of clip position is a key wherein during unloading spring-back, in reality processing, is closed after the completion of milling
Vacuum suction system is closed, workpiece is on vacuum platform without constraint free deformation, now needing will be above all of
Constraint is cancelled, while the rigid body displacement in order to eliminate workpiece, emulates feature, it is necessary in workpiece bottom selection plate with reference to resilience
Five points of crux of heart shape, as shown in figure 5, the displacement and rotation of 5 points of constraint, wherein only central point use is completely fixed constraint,
The constraint principle of other points is that its constraint reduces the influence to resilience to greatest extent.For example, with reference to shown in Fig. 5, to described
The constraints of five points is：Central point is completely fixed；2 points be distributed with X-direction with respect to central point, its Y direction
The translation freedoms and rotary freedom in direction suffers restraints around X-direction and about the z axis；With respect to central point with Y direction point
2 points of cloth, translation freedoms of its X-direction and rotary freedom in direction suffers restraints around Y direction and about the z axis；Its
Middle X-direction, Y direction, Z-direction are mutually perpendicular to, and Y direction is the direction of plate roll bending.That is, the X-direction of central point
2 points of boundary condition can be U2=UR1=UR3=0,2 points of the Y-direction of central point of boundary condition is U1=UR2=
UR3=0.Wherein, U represents translation freedoms, and UR represents rotational freedom, and 1,2,3 represent X, Y, Z axis direction respectively.Above-mentioned side
Boundary's condition is used to constrain the displacement with the perpendicular direction of plate roll bending direction of feed and the other two in addition to roller direction of rotation
The rotary freedom in direction, the displacement and rotation of 5 points of constraint, realizes the resilience after plate trimming, milling.
The finite element simulation method of roll bending-milling process of the large scale of the invention with step thin-wall part, takes full advantage of
Some characteristics of roll bending-milling process of the large scale with step thin-wall part improve the efficiency of finite element simulation method, while protect
Demonstrate,prove its accuracy
First, by taking roll bending model as an example, the foundation of roll bending model more accurately by the residual stress after roll bending and should be returned
Bullet is moved into Data Model, to realize the accurate description of the resilience that material causes after removing to Stress Release and redistribution, together
When plate center section is concentrated on due to roll bending process primary deformable region, along the curvature at the front and rear edges of feedstock direction very
It is small, so after the roll bending deformation for completing large size plate, the present invention removes edge straight portion by trimming, in the middle of reservation
Even deformed region, and the simulation of trimming process is realized by Sub-model Technology
Secondly as Milling Processes be one be related to deform, be broken, the crowd such as dynamics, nonlinear contact, heat transfer
Many complicated physical phenomenas, while again comprising the process of all too many levels of process system such as lathe, cutter, fixture, workpiece, therefore to build
It is extremely difficult to found the simulation model of accurate Milling Process technical process, it usually needs before analysis result precision is ensured
Put, these complicated physical conditions are carried out with certain numerical value and is simplified.For the present invention, present invention utilizes large scale
, normally close in single-curvature band step thin-wall part, milling amount is smaller in its milling process, and Milling Force is smaller for band step thin-wall part, because
The milling heat that this is produced is less, and generally can all be cooled down with cutting fluid and good cooling results always in process, in this hair
Ignore the influence of milling heat in bright, meanwhile, the influence of strain rate can also be ignored, thus use elastic-plastic material model.
Additionally, for body unit model, typical material removing method is element birth and death technology, but use body unit meter
Have the shortcomings that to use shell unit in computational efficiency low and easy generation hourglass phenomenon, therefore the present invention in calculation roll bending model process
It is simulated, it is by the thickness value of change tape step thin-wall structure different zones shell unit and complete with reference to submodel technology of reruning
Into lathe simulation.The method substantially increases computational efficiency while computational accuracy is ensured, has saved calculating cost.
Although the foregoing describing specific embodiment of the invention, it will be appreciated by those of skill in the art that these
It is merely illustrative of, protection scope of the present invention is defined by the appended claims.Those skilled in the art is not carrying on the back
On the premise of principle of the invention and essence, various changes or modifications can be made to these implementation methods, but these are changed
Protection scope of the present invention is each fallen within modification.
Claims (9)
1. the finite element simulation method of roll bending-milling process of a kind of large scale with step thin-wall part, it is characterised in that described to have
The first emulation mode of limit is comprised the following steps：
Step one, the roll bending model for setting up plate, the plate are elasticoplastic body, and are carried out using linear decrement integration shell unit
Mesh generation, the roll bending model is used to simulating the roll bending process of plate, the roll bending process include the bending of plate, roll bending and
Resilience；
Step 2, based on the result after roll bending process described in the roll bending modeling, trimming is simulated by Sub-model Technology
Journey, wherein trimming process remove the edge straight portion of plate and retain middle homogeneous deformation region, then according to described big
What design of part of the size with step thin-wall part was partitioned into plate treats milling region, and changes the shell unit of the different zones of plate
Thickness value, to simulate milling process of the large scale with step thin-wall part；
Step 3, the workpiece obtained based on step 2 simulation milling process, carry out the simulation of springback process, the simulation of springback process
Including closing vacuum suction system, the workpiece for obtaining milling is in without constraint free deformation, in institute on vacuum platform
The center of bottom surface selection plate of workpiece is stated in criss-cross five points, the displacement of five points is constrained and is rotated to carry out
Springback calculation after plate milling, wherein be that central point is completely fixed to the constraints of five points, and other four
Point is then confined to reduce the influence to resilience to greatest extent.
2. finite element simulation method as claimed in claim 1, it is characterised in that to its in five points in addition to central point
He is at the constraints of four points：
With respect to central point with 2 points of the first axial distribution, the translation freedoms of its second axial direction and around first axially and around the
The rotary freedom of three axial directions suffers restraints；
With respect to central point with 2 points of the second axial distribution, the translation freedoms of its first axial direction and around second axially and around the
The rotary freedom of three axial directions suffers restraints；
Wherein first axial direction, the second axial direction, the 3rd are axially mutually perpendicular to, and second is axially the direction of plate roll bending.
3. finite element simulation method as claimed in claim 1, it is characterised in that in step one, one is modeled using discrete rigid body
Individual upper roller, two bottom rolls as the part for coming in contact and extruding with plate, and according to large scale with step thin-wall part
The motion of roll forming process control roller, simulates roll bending process.
4. finite element simulation method as claimed in claim 1, it is characterised in that the simulation of the roll bending process includes following three
Individual analysis step：
The first step, the upper roller is pushed to cause sheet metal bending, is realized to roll bending process by the volume under pressure of the upper roller of adjustment
Bending radius control；
Second step, the upper roller keeps pressed status constant and rotation, and the rolling of plate is realized by the CONTACT WITH FRICTION with plate
Curved, the bottom roll is servo-actuated so that plate roll bending by a lateral edges, the upper roller is anti-after roll bending to another lateral edges
Turn, the original position for returning to pressed status stops；
3rd step, roll bending terminates, the upper roller lifting, and plate occurs resilience.
5. finite element simulation method as claimed in claim 1, it is characterised in that in step one, opens the enhancing control of hourglass rigidity
There is hourglass with plate in avoiding the roll bending process in system.
6. finite element simulation method as claimed in claim 1, it is characterised in that the finite element simulation method uses ABAQUS
Software implementation.
7. finite element simulation method as claimed in claim 6, it is characterised in that the calculating in step one uses explicit algorithm
Explicit is calculated.
8. finite element simulation method as claimed in claim 6, it is characterised in that simulated using Static implicit algorithm in step 3
Springback process.
9. finite element simulation method as claimed in claim 1, it is characterised in that the large scale band step thin-wall part is single
Rate band step thin-wall part.
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| CN112058961A (en) * | 2020-08-20 | 2020-12-11 | 中国商用飞机有限责任公司 | Method, apparatus and medium for roll forming of monolithic wall panels |
| CN114429065A (en) * | 2022-01-07 | 2022-05-03 | 西北工业大学 | Finite element-based method for calibrating resilience of contact material of flank face in micro-milling process |
| CN115091129A (en) * | 2022-06-22 | 2022-09-23 | 四川航天长征装备制造有限公司 | Roll bending and shape correcting process method for aluminum alloy wall plate |
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| CN112058961A (en) * | 2020-08-20 | 2020-12-11 | 中国商用飞机有限责任公司 | Method, apparatus and medium for roll forming of monolithic wall panels |
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| CN114429065B (en) * | 2022-01-07 | 2024-02-23 | 西北工业大学 | Method for calibrating rebound of contact material of rear tool face in micro-milling process based on finite element |
| CN115091129A (en) * | 2022-06-22 | 2022-09-23 | 四川航天长征装备制造有限公司 | Roll bending and shape correcting process method for aluminum alloy wall plate |
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