CN112439834A - Self-resistance electric heating intelligent incremental forming method - Google Patents

Self-resistance electric heating intelligent incremental forming method Download PDF

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CN112439834A
CN112439834A CN202011177416.2A CN202011177416A CN112439834A CN 112439834 A CN112439834 A CN 112439834A CN 202011177416 A CN202011177416 A CN 202011177416A CN 112439834 A CN112439834 A CN 112439834A
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CN112439834B (en
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鲁世红
李正芳
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Suzhou Research Institute Of Nanjing University Of Aeronautics And Astronautics
Nanjing University of Aeronautics and Astronautics
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
    • B21D31/005—Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/16—Heating or cooling
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
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    • G06F30/17—Mechanical parametric or variational design
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
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    • G06F—ELECTRIC DIGITAL DATA PROCESSING
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    • G06F2113/22—Moulding
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    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
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    • G06F—ELECTRIC DIGITAL DATA PROCESSING
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    • G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces

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Abstract

The invention discloses a self-resistance electric heating intelligent incremental forming method, which comprises the following steps: establishing a calculation model of the volume change rate (dV/dt) of a deformation area according to the space geometric change characteristics of a contact area between a forming tool and a sheet material in incremental forming; and B: establishing a calculation model of the resistance (Rs) and the contact resistance (Rj) of the material in the contact area according to the circuit characteristics of the contact area in the self-resistance electric heating progressive forming; and C: establishing an instantaneous Joule thermal model (Q) between a forming tool and a plate contact area and an equivalent calculation model (K) of a contact heat conduction coefficient; step D: substituting the related parameters into a user subprogram ABAQUS-VUINTER to obtain a local deformation temperature value; the invention can effectively solve the difficulty of electric-thermal-force three-field coupling numerical simulation, and combines the simulation result with the forming equipment, thereby realizing the process of simulation-manufacture integration and improving the processing efficiency and the intellectualization of the forming process.

Description

Self-resistance electric heating intelligent incremental forming method
Technical Field
The invention relates to a progressive forming method, in particular to a self-resistance electric heating intelligent progressive forming method, and belongs to the technical field.
Background
The incremental forming technology for metal plate is a new flexible dieless forming technology for plate-shell type parts by combining rapid prototyping and plastic forming, is proposed by American scholars Leszak in the last 60 th century, and Japanese scholars Kitazawa successfully applies the technology to process aluminum alloy test pieces in the last 90 th century. Through research in recent 20 years, the progressive forming technology gradually goes from experimental research to practical application, and the change of the sheet forming from linearization in the process of design-manufacture to integration is realized. The method can effectively shorten the life cycle of product manufacture, reduce energy consumption in the whole production cycle, improve the forming limit and forming performance of the material, and has wide application potential in the fields of aerospace, transportation, energy equipment, medical treatment and the like.
The metal plate incremental forming technology is mainly applied to the fields of forming of covering parts of automobiles and high-speed trains, manufacturing of airplane covering parts and the like, and can also be applied to manufacturing of yacht hulls, pressure containers, architectural decoration, urban sculpture and processing and manufacturing of various curved surface metal plate parts in medical engineering. In the development of new products, the sheet metal parts account for a large proportion, so that the types of the parts are more. For individual small-batch products, multiple sets of dies need to be developed by using the traditional forming process, which results in high manufacturing cost and long manufacturing period of parts. The progressive forming process usually adopts a non-mold or half-mold machining process, and the manufacturing precision requirement and the manufacturing cost of the supporting explorator are low. Therefore, the numerical control incremental forming technology for the metal plate can realize product design-manufacturing integration and reduce the manufacturing cost and period of the product.
Aiming at the characteristics of poor room-temperature forming capability and good high-temperature forming performance of light alloy materials, a thermal incremental forming technology is required for processing. The electric auxiliary technology has the characteristics of high heating efficiency, high plate heating rate, low processing cost, high flexibility and the like, and is widely applied to a progressive forming process for processing difficult-to-form materials, namely a self-resistance electric heating progressive forming technology. At present, the self-resistance electric heating incremental forming technology relates to an electric-thermal-force three-field coupling effect, accurate analysis of the technology cannot be realized by using a conventional numerical simulation method, and further the reasonable configuration of parameters of the self-resistance electric heating incremental forming technology cannot be quickly guided by using the numerical simulation method, so that the manufacturing efficiency and the intellectualization of the whole technology are reduced. The invention aims to provide an electric-thermal-force coupled numerical simulation method for self-resistance electric heating incremental forming, and realizes the integrated combination of numerical simulation and manufacturing, thereby forming a rapid intelligent manufacturing technology of a light alloy material.
Disclosure of Invention
The invention aims to provide a self-resistance electric heating intelligent incremental forming method to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a self-resistance electric heating intelligent incremental forming method comprises the following steps:
step A: defining a volume rate of change model (dV/dt) for the deformation region;
and B: defining the equivalent resistance of the deformation region, namely the resistance (Rs) and the contact resistance (Rj) of the material in the deformation region according to the circuit characteristics of the contact region in the self-resistance electric heating progressive forming;
and C: defining an instantaneous Joule thermal model (dQ) and an equivalent contact thermal conductivity model (K) in a deformation area according to the Joule thermal phenomenon in the deformation area;
step D: substituting the model dV/dt obtained in the step A, the models Rs and Rj obtained in the step B and the models dQ and K obtained in the step C into a subprogram ABAQUS-VUINTER through finite element software so as to accurately simulate the Joule heating effect of a contact area between a forming tool and a plate;
step E: and inputting the technological parameters obtained by numerical simulation into processing equipment so as to realize rapid forming of the part.
As a preferred technical scheme of the invention, in the step A, the volume change rate dV/dt of the deformation region is determined as undetermined parameters by the feeding rate (v) of the forming tool, the radius (rT) of the forming tool, geometric constants (a and b) and an included angle (theta, phi) between the inner surface and the outer surface of the deformation region and the central line of the forming tool; the volume change rate dV/dt is shown by the formula (1):
Figure BDA0002749094220000031
in the formula: theta1And theta2Respectively the included angle phi between the inner surface and the central line of the cutter1And phi2Respectively, the included angles between the outer surface and the center line of the cutter, and a and b are constants related to the thickness of the plate, rT and phi.
In the step B, the resistance (Rs) and the contact resistance (Rj) of the material in the deformation area take the forming temperature as an internal variable, wherein the Rs takes the resistivity of the material, the thickness and the volume change rate of the material in the deformation area as undetermined parameters, and the Rj takes the contact resistance and the hardness of the material as undetermined parameters; rs and Rj are represented by formulas (2) and (3), respectively:
Figure BDA0002749094220000032
Figure BDA0002749094220000033
wherein ρ s (T) and H (T) are temperature-dependent resistivity and hardness, respectively, and H (Tr) is contact resistance and hardness of the material at room temperature, respectively, and tg is the thickness of the deformation zone.
As a preferred technical scheme of the invention, in the step C, the instantaneous Joule thermal model (dQ) of the deformation area takes the current intensity, the equivalent resistance and the current action time as undetermined parameters, the equivalent contact heat conduction coefficient model (K) takes the temperature of a forming tool and the initial temperature of a plate as internal variables, and takes the current intensity, the equivalent resistance, the thickness of the plate in the deformation area and the volume change rate as undetermined parameters; dQ and K are represented by formulas (4) and (5), respectively:
dQ＝I2·(Rs+Rj)·dt (4)
Figure BDA0002749094220000041
wherein TT and Ts are the temperature of the forming tool and the initial temperature of the plate respectively.
As a preferred technical solution of the present invention, the specific process of step D is: and substituting the model dV/dt obtained in the step A, the models Rs and Rj obtained in the step B and the models dQ and K obtained in the step C into a user subprogram ABAQUS-VUINTER by adopting ABAQUS software, simulating the Joule heat effect of the contact area of the forming tool and the plate, comparing with the test result, analyzing the error and verifying the accuracy of the numerical simulation method.
As a preferred technical scheme of the invention, the forming process parameters obtained by numerical simulation and CNC codes are input into forming equipment, and forming tools, pressing amount, feeding speed, current intensity and processing tracks in the forming process are quickly set, so that the quick and intelligent manufacturing of parts is realized.
Compared with the prior art, the invention has the beneficial effects that:
the invention relates to a self-resistance electric heating intelligent incremental forming method, which considers the influence of process parameters on the volume change of a deformation area in incremental forming, provides a volume change rate model of the deformation area, considers the change of electric and mechanical properties along with temperature under the action of current, realizes the prediction of the Joule heating effect of the deformation area, has more accurate result, adopts a user subprogram of a display algorithm to carry out secondary development on software, improves the usability, the universality and the reliability of finite element simulation software, provides a basic implementation method for researching the electric-heat-force three-field coupling under the electric auxiliary forming of difficult-to-process materials, and enlarges the application range.
Drawings
FIG. 1 is a flow chart of a numerical simulation method of the joule heating effect in the self-resistance electric heating incremental forming according to the present invention;
FIG. 2 is a table showing an error analysis of the stable simulated temperature of the deformation zone after the application of the current.
Detailed Description
The existing research shows that the self-resistance electric heating progressive forming middle joule heating effect is a self-resistance electric heating phenomenon in a deformation area, and the temperature rise effect of the deformation area changes along with the changes of equivalent resistance, current intensity and the space size of the deformation area. However, the existing research usually uses trial and error to set the magnitude of heat flow to describe the temperature change of the deformation region.
The numerical simulation method for the self-resistance electric heating incremental forming middle focal ear effect is characterized in that the relation among electric field parameters, deformation area volume change and forming process parameters is considered, and the software is developed secondarily by using an ABAQUS-VUI user sub-program of a display algorithm.
Referring to fig. 1-2, the present invention provides a technical solution of a self-resistance electrical heating intelligent incremental forming method:
according to the figures 1-2, a self-resistance electric heating intelligent incremental forming method comprises the following steps:
step A: defining a volume rate of change model (dV/dt) for the deformation region;
and B: defining the equivalent resistance of the deformation region, namely the resistance (Rs) and the contact resistance (Rj) of the material in the deformation region according to the circuit characteristics of the contact region in the self-resistance electric heating progressive forming;
and C: defining an instantaneous Joule thermal model (dQ) and an equivalent contact thermal conductivity model (K) in a deformation area according to the Joule thermal phenomenon in the deformation area;
step D: substituting the model dV/dt obtained in the step A, the models Rs and Rj obtained in the step B and the models dQ and K obtained in the step C into a subprogram ABAQUS-VUINTER through finite element software so as to accurately simulate the Joule heating effect of a contact area between a forming tool and a plate;
step E: and inputting the technological parameters obtained by numerical simulation into processing equipment so as to realize rapid forming of the part.
According to the drawings of fig. 1-2, in step a, the volume change rate dV/dt of the deformation region is determined by the feed rate (v) of the forming tool, the radius (rT) of the forming tool, the geometric constants (a and b) and the included angle (θ, φ) between the inner and outer surfaces of the deformation region and the centerline of the forming tool; the volume change rate dV/dt is shown by the formula (1):
Figure BDA0002749094220000061
in the formula: theta1And theta2Respectively the included angle phi between the inner surface and the central line of the cutter1And phi2Respectively, the included angles between the outer surface and the center line of the cutter, and a and b are constants related to the thickness of the plate, rT and phi.
In the step B, the resistance (Rs) and the contact resistance (Rj) of the material in the deformation area take the forming temperature as an internal variable, wherein the Rs takes the resistivity of the material, the thickness and the volume change rate of the material in the deformation area as undetermined parameters, and the Rj takes the contact resistance and the hardness of the material as undetermined parameters; rs and Rj are represented by formulas (2) and (3), respectively:
Figure BDA0002749094220000062
Figure BDA0002749094220000063
wherein ρ s (T) and H (T) are temperature-dependent resistivity and hardness, respectively, and H (Tr) is contact resistance and hardness of the material at room temperature, respectively, and tg is the thickness of the deformation zone.
In the step C, the instantaneous Joule thermal model (dQ) of the deformation area takes the current intensity, the equivalent resistance and the current action time as undetermined parameters, the equivalent contact heat conduction coefficient model (K) takes the temperature of a forming tool and the initial temperature of a plate as internal variables, and takes the current intensity, the equivalent resistance, the thickness of the plate in the deformation area and the volume change rate as undetermined parameters; dQ and K are represented by formulas (4) and (5), respectively:
dQ＝I2·(Rs+Rj)·dt (4)
Figure BDA0002749094220000071
wherein TT and Ts are the temperature of the forming tool and the initial temperature of the plate respectively.
The specific process of the step D is as follows: and substituting the model dV/dt obtained in the step A, the models Rs and Rj obtained in the step B and the models dQ and K obtained in the step C into a user subprogram ABAQUS-VUINTER by adopting ABAQUS software, simulating the Joule heat effect of the contact area of the forming tool and the plate, comparing with the test result, analyzing the error and verifying the accuracy of the numerical simulation method.
And inputting the forming process parameters obtained by numerical simulation and CNC codes into forming equipment, and quickly setting a forming tool, a pressing amount, a feeding speed, current intensity and a machining track in the forming process to realize quick and intelligent manufacturing of parts.
The superiority of the numerical simulation method of joule heating effect in self-resistance electric heating incremental forming according to the present invention in practical application will be described by an example.
The analysis case is formed by the self-resistance electrical heating progressive forming of the titanium alloy conical part, wherein the thickness of a plate is 0.5mm, the current intensity is 230A, the feeding rate is 500mm/min, the pressing amount is 0.15mm, the radius of a forming tool is 5mm, the forming angle of the part is 45 degrees, and the actual measurement temperature of the forming temperature is collected by a thermal imaging instrument.
According to the formula (1), the volume change rate dV/dt of the forming tool and the sheet deformation area is 29.85mm3/s according to the forming angle, the pressing amount, the forming tool radius and the material thickness of the part.
And (3) acquiring the node temperature of a contact area between the forming tool and the sheet material in the simulation process in real time by using finite element simulation software, and updating the material resistance, the contact resistance and the Joule heat of a deformation area in the forming process in real time according to a formula (2), a formula (3) and a formula (4) in an ABAQUS-VULDER subprogram.
And (3) further substituting the calculation result into a formula (5) so as to update the contact heat conduction coefficient of the contact area between the forming tool and the sheet in the numerical simulation, and calculating the heat flow of the sheet deformation area in real time by combining the contact heat conduction principle.
And (3) comparing the numerical simulation with the actually measured temperature distribution, carrying out numerical simulation on the joule heating effect in the titanium alloy self-resistance electric heating incremental forming by calling an ABAQUS-VULTER user sub-program in finite element software, comparing with a test result to know that the temperature distribution is consistent, and controlling the error of the highest temperature within 5 percent. Meanwhile, table 1 shows the error analysis of the stable simulated temperature of the deformation region after the current action, the stable temperatures of the first five layers of four quadrant points of the forming region are respectively collected, and the average error is about 5%, which indicates that the model can effectively simulate the joule heating effect of the deformation region in the forming process.
Selecting a better numerical simulation result, obtaining reasonable configuration of forming process parameters (diameter of a forming tool, pressing amount, feeding speed and current intensity), further converting linear codes of a numerical simulation track into CNC codes which can be identified by forming equipment, and finally transmitting the data into the forming equipment, thereby realizing the rapid and intelligent manufacturing of the titanium alloy part.
In conclusion, the invention considers the relation among the electric field parameters, the volume change of the deformation area and the forming process parameters, provides a corresponding calculation model, considers the influence of the temperature change of the deformation area, better accords with the actual situation, has more accurate result, adopts the user subprogram of the display algorithm to carry out secondary development on software, improves the availability, the universality and the reliability of finite element software, combines the numerical simulation result with the forming equipment, realizes the quick and intelligent manufacture of light alloy materials, provides an intelligent manufacturing method for researching the electric auxiliary processing process of other materials, and enlarges the flexibility of the process
In the description of the present invention, it is to be understood that the indicated orientations or positional relationships are based on the orientations or positional relationships shown in the drawings and are only for convenience in describing the present invention and simplifying the description, but are not intended to indicate or imply that the indicated devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and are not to be construed as limiting the present invention.
In the present invention, unless otherwise explicitly specified or limited, for example, it may be fixedly attached, detachably attached, or integrated; can be mechanically or electrically connected; the terms may be directly connected or indirectly connected through an intermediate, and may be communication between two elements or interaction relationship between two elements, unless otherwise specifically limited, and the specific meaning of the terms in the present invention will be understood by those skilled in the art according to specific situations.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

Claims (6)

1. A self-resistance electric heating intelligent incremental forming method is characterized by comprising the following steps:
step A: defining a volume rate of change model (dV/dt) for the deformation region;
and B: defining the equivalent resistance of the deformation region, namely the resistance (Rs) and the contact resistance (Rj) of the material in the deformation region according to the circuit characteristics of the contact region in the self-resistance electric heating progressive forming;
and C: defining an instantaneous Joule thermal model (dQ) and an equivalent contact thermal conductivity model (K) in a deformation area according to the Joule thermal phenomenon in the deformation area;
step D: substituting the model dV/dt obtained in the step A, the models Rs and Rj obtained in the step B and the models dQ and K obtained in the step C into a subprogram ABAQUS-VUINTER through finite element software so as to accurately simulate the Joule heating effect of a contact area between a forming tool and a plate;
step E: and inputting the technological parameters obtained by numerical simulation into processing equipment so as to realize rapid forming of the part.
2. The intelligent incremental forming method by self-resistance electric heating according to claim 1, wherein in the step A, the volume change rate dV/dt of the deformation region is determined by the feeding rate (v) of the forming tool, the radius (rT) of the forming tool, geometric constants (a and b) and the included angle (theta, phi) between the inner surface and the outer surface of the deformation region and the central line of the forming tool as undetermined parameters; the volume change rate dV/dt is shown by the formula (1):
Figure FDA0002749094210000011
in the formula: theta1And theta2Respectively the included angle phi between the inner surface and the central line of the cutter1And phi2Respectively, the included angles between the outer surface and the center line of the cutter, and a and b are constants related to the thickness of the plate, rT and phi.
3. The intelligent incremental forming method through self-resistance electric heating according to claim 1, wherein in the step B, the forming temperature is used as an internal variable for the resistance (Rs) and the contact resistance (Rj) of the material in the deformation area, wherein the resistivity of the material is used as the Rs, the thickness and the volume change rate of the material in the deformation area are undetermined parameters, and the contact resistance and the hardness of the material are undetermined parameters for the Rj; rs and Rj are represented by formulas (2) and (3), respectively:
Figure FDA0002749094210000021
Figure FDA0002749094210000022
wherein ρ s (T) and H (T) are temperature-dependent resistivity and hardness, respectively, and H (Tr) is contact resistance and hardness of the material at room temperature, respectively, and tg is the thickness of the deformation zone.
4. The self-resistance electric heating intelligent incremental forming method according to claim 1, wherein in the step C, the instantaneous Joule thermal model (dQ) of the deformation area takes the current intensity, the equivalent resistance and the current action time as undetermined parameters, the equivalent contact heat conduction coefficient model (K) takes the forming tool temperature and the sheet initial temperature as internal variables, and takes the current intensity, the equivalent resistance, the thickness of the deformed area and the volume change rate as undetermined parameters; dQ and K are represented by formulas (4) and (5), respectively:
dQ＝ρ·(Ri+Rj)·dt (4)
Figure FDA0002749094210000023
in the formula, TTAnd Ts is the forming tool temperature and the sheet metal initial temperature, respectively.
5. The self-resistance electric heating intelligent incremental forming method according to claim 1, wherein the specific process of the step D is as follows: and substituting the model dV/dt obtained in the step A, the models Rs and Rj obtained in the step B and the models dQ and K obtained in the step C into a user subprogram ABAQUS-VUINTER by adopting ABAQUS software, simulating the Joule heat effect of the contact area of the forming tool and the plate, comparing with the test result, analyzing the error and verifying the accuracy of the numerical simulation method.
6. The self-resistance electric heating intelligent incremental forming method according to claim 5, wherein the specific process of the step E is as follows: and inputting the forming process parameters obtained by numerical simulation and CNC codes into forming equipment, and quickly setting a forming tool, a pressing amount, a feeding speed, current intensity and a machining track in the forming process to realize quick and intelligent manufacturing of parts.
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