CN112439834B - Self-resistance electric heating intelligent incremental forming method - Google Patents
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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
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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
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Abstract
The invention discloses a self-resistance electric heating intelligent incremental forming method, which comprises the following steps: according to the space geometric change characteristics of a contact area between a forming tool and a plate in incremental forming, establishing a calculation model of the volume change rate (dV/dt) of a deformation area; and (B) step (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 self-resistance electric heating incremental forming; step C: establishing an instantaneous joule heating model (Q) between the forming tool and the plate contact area and an equivalent calculation model (K) of the contact heat conduction coefficient; step D: substituting the related parameters into a user subroutine 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, combines the simulation result with forming equipment, realizes the simulation-manufacturing integrated process, and improves the processing efficiency and the intellectualization of the forming process.
Description
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 metal sheet incremental forming technology is a new flexible die-free forming technology for plate and shell parts by combining rapid prototyping with plastic forming, and is proposed by American scholars Leszak in the 60 th century, and Japanese scholars Kitazawa successfully use the technology to process aluminum alloy test pieces in the 90 th century. Through researches for nearly 20 years, the incremental forming technology gradually goes from experimental researches to practical application, and the conversion from linearization to integration of the plate forming in the process of design and manufacturing is realized. The method can effectively shorten the life cycle of product manufacture, reduce the energy consumption in the whole production cycle, improve the forming limit and the 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 automobiles, high-speed train covering piece forming, aircraft skin part manufacturing and the like, and can also be applied to the manufacturing of various curved sheet metal parts in yacht hull manufacturing, pressure vessels, building decoration, urban sculpture and medical engineering. In the research and development of new products, the metal plate parts have large proportion, so that the types of the parts are more. For personalized small lot products, multiple sets of dies need to be developed using traditional forming processes, which can result in high part manufacturing costs and long manufacturing cycles. The progressive forming process generally adopts a die-free or half-mould processing, and the manufacturing precision requirement and the manufacturing cost of the support explorator are low. Therefore, the numerical control incremental forming technology of the metal plate can not only realize the integration of product design and manufacture, but also reduce the manufacturing cost and period of the product.
Aiming at the light alloy material, the material has the characteristics of poor room temperature forming capability and good high temperature forming performance, and needs to be processed by adopting a thermal progressive forming technology. Because the electric auxiliary technology has the characteristics of high heating efficiency, high plate heating rate, low processing cost, high flexibility and the like, the electric auxiliary technology is widely applied to the progressive forming technology for processing difficult-to-form materials, namely the self-resistance electric heating progressive forming technology. At present, the self-resistance electric heating incremental forming technology relates to three-field coupling effect of electricity, heat and force, and the accurate analysis of the technology cannot be realized by utilizing a conventional numerical simulation method, so that the reasonable configuration of the self-resistance electric heating incremental forming technological parameters cannot be rapidly guided by utilizing the numerical simulation method, and the manufacturing efficiency and the intellectualization of the whole technology are reduced. The invention aims to provide an electric-thermal-force coupling numerical simulation method for self-resistance electric heating incremental forming, and realizes the integration 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 for solving the problems in the background technology.
In order to achieve the above purpose, the present invention provides the following technical solutions: a self-resistance electric heating intelligent incremental forming method comprises the following steps:
step A: defining a volume change rate model (dV/dt) of the deformation region;
and (B) step (B): according to the circuit characteristics of the contact area in self-resistance electric heating incremental forming, the equivalent resistance of the deformation area, namely the resistance (R s ) With contact resistance (R) j )；
Step C: defining a deformation region instantaneous joule heating model (dQ) and an equivalent contact heat conduction coefficient model (K) according to the joule heating phenomenon of the deformation region;
step D: the model dV/dt obtained in the step A and the model R obtained in the step B are processed through finite element software s And R is j C, substituting the obtained models dQ and K into a subroutine ABAQUS-VUINTER to accurately simulate the Joule heating effect of the contact area of the forming tool and the plate;
step E: and inputting the technological parameters obtained by numerical simulation into processing equipment so as to realize the rapid forming of the parts.
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, the geometric constants (a and b) and the included angles (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 represented by formula (1):
wherein: θ 1 And theta 2 Respectively the included angles phi between the inner surface and the central line of the cutter 1 And phi 2 The angles between the outer surface and the center line of the cutter are respectively, and a and b are constants related to the thickness of the plate material, rT and phi.
In step B, as a preferred embodiment of the present invention, the resistance (R s ) With contact resistance (R) j ) With forming temperature as internal variable, where R s The material resistivity, the material thickness and the volume change rate of the deformation zone are used as undetermined parameters, R j Taking the contact resistance and hardness of the material as undetermined parameters; r is R s And R is j As shown in the formula (2) and the formula (3), respectively:
wherein ρ is s (T) and H (T) are respectively the resistivity and the hardness which are temperature dependent, R j (T r ) And H (T) r ) Respectively the contact resistance and the hardness of the material at room temperature, t g Is the material 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 acting time as undetermined parameters, the equivalent contact thermal conductivity coefficient model (K) takes the forming tool temperature and the initial temperature of the plate as internal variables, and the current intensity, the equivalent resistance, the thickness of the deformation area and the volume change rate as undetermined parameters; dQ and K are represented by the following formulas (4) and (5), respectively:
dQ＝I 2 ·(R s +R j )·dt (4)
wherein T is T And T s The temperature of the forming tool and the initial temperature of the sheet material are respectively.
As a preferable technical scheme of the invention, the specific process of the step D is as follows: and (3) adopting ABAQUS software to obtain the model dV/dt obtained in the step A and the model obtained in the step BR s And R is j And C, substituting the obtained models dQ and K into a user subroutine ABAQUS-VUINTER, simulating the Joule heating effect of the contact area of the forming tool and the plate, comparing the simulated Joule heating effect with a test result, analyzing errors, and verifying the accuracy of the numerical simulation method.
As a preferable technical scheme of the invention, the forming process parameters and CNC codes obtained by numerical simulation are input into forming equipment, and the forming tools, the pressing quantity, the feeding speed, the current intensity and the processing track in the forming process are rapidly set, so that the rapid and intelligent manufacturing of the parts is realized.
Compared with the prior art, the invention has the beneficial effects that:
the invention provides 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 deformation area volume change rate model, 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 subroutine of a display algorithm to secondarily develop software, improves the usability, the universality and the reliability of finite element simulation software, provides a basic implementation method for researching three-field coupling under electric auxiliary forming of difficult-to-process materials, and expands the application range.
Drawings
FIG. 1 is a flow chart of a method for simulating the value of the Joule heating effect in 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 current is applied.
Detailed Description
The prior study shows that the joule heating effect in the self-resistance heating incremental forming is based on the self-resistance heating phenomenon of the deformation area, and the temperature rise effect of the deformation area changes along with the change of the equivalent resistance, the current intensity and the space dimension of the deformation area. Whereas prior studies have generally set the heat flow level in a trial and error manner to describe the temperature change in the deformation zone.
The numerical simulation method of the joule effect in self-resistance electric heating incremental forming is characterized by taking the relation among electric field parameters, deformation region volume change and forming process parameters into consideration, and performing secondary development on software by using an ABAQUS-VUINTER user subroutine of a display algorithm.
Referring to fig. 1-2, the present invention provides a self-resistance electric heating intelligent incremental forming method, which comprises:
according to the method shown in fig. 1-2, a self-resistance electric heating intelligent incremental forming method comprises the following steps:
step A: defining a volume change rate model (dV/dt) of the deformation region;
and (B) step (B): according to the circuit characteristics of the contact area in self-resistance electric heating incremental forming, the equivalent resistance of the deformation area, namely the resistance (R s ) With contact resistance (R) j )；
Step C: defining a deformation region instantaneous joule heating model (dQ) and an equivalent contact heat conduction coefficient model (K) according to the joule heating phenomenon of the deformation region;
step D: substituting the model dV/dt obtained in the step A, the model Rs and Rj obtained in the step B and the model dQ and K obtained in the step C into a subroutine ABAQUS-VINTER through finite element software so as to accurately simulate the Joule heating effect of the contact area between the forming tool and the plate;
step E: and inputting the technological parameters obtained by numerical simulation into processing equipment so as to realize the rapid forming of the parts.
1-2, in the step A, the volume change rate dV/dt of the deformation region is determined by the forming tool feeding rate (v), the forming tool radius (rT), the 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 represented by formula (1):
wherein: θ 1 And theta 2 Respectively the included angles phi between the inner surface and the central line of the cutter 1 And phi 2 Respectively is externally provided withThe angle between the surface and the centre line of the tool, a and b, are constants related to the thickness of the plate, rT and phi.
In step B, the resistance (R s ) With contact resistance (R) j ) With forming temperature as internal variable, where R s The material resistivity, the material thickness and the volume change rate of the deformation zone are used as undetermined parameters, R j Taking the contact resistance and hardness of the material as undetermined parameters; r is R s And R is j As shown in the formula (2) and the formula (3), respectively:
wherein ρ is s (T) and H (T) are respectively the resistivity and the hardness which are temperature dependent, R j (T r ) And H (T) r ) Respectively the contact resistance and the hardness of the material at room temperature, t g Is the material 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 acting time as undetermined parameters, the equivalent contact thermal conductivity coefficient model (K) takes the forming tool temperature and the initial temperature of the plate as internal variables, and the current intensity, the equivalent resistance, the material thickness of the deformation area and the volume change rate as undetermined parameters; dQ and K are represented by the following formulas (4) and (5), respectively:
dQ＝I 2 ·(R s +R j )·dt (4)
wherein T is T And T s The temperature of the forming tool and the initial temperature of the sheet material are respectively.
The specific process of the step D is as follows: and (3) adopting ABAQUS software to obtain the model dV/dt obtained in the step A and the model R obtained in the step B s And R is j Step (a)And C, substituting the obtained models dQ and K into a user subroutine ABAQUS-VUINTER, simulating the Joule heating effect of the contact area of the forming tool and the plate, comparing the simulated Joule heating effect with a test result, analyzing errors, and verifying the accuracy of the numerical simulation method.
And (3) inputting the forming technological parameters and CNC codes obtained by numerical simulation into forming equipment, and rapidly setting forming tools, pressing quantity, feeding speed, current intensity and processing track in the forming process, so as to realize rapid and intelligent manufacturing of the parts.
The following describes the superiority of a numerical simulation method of joule heating effect in self-resistance electric heating incremental forming in practical application by an embodiment.
The self-resistance electric heating incremental forming of the titanium alloy conical part is used as an analysis case, 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 a part is 45 degrees, and the actual measurement temperature of the forming temperature is acquired by a thermal imager.
According to formula (1), the volume change rate dV/dt=29.85 mm3/s of the deformation region of the forming tool and the sheet material is obtained by combining the forming angle, the pressing amount, the forming tool radius and the material thickness of the part.
And acquiring the node temperature of the contact area of the forming tool and the plate in the simulation process in real time by utilizing finite element simulation software, and updating the material resistance, the contact resistance and the Joule heat of the deformation area in the forming process in real time according to the formula (2), the formula (3) and the formula (4) in an ABAQUS-Vuser subroutine.
And (3) further substituting the calculation result into a formula (5) so as to update the contact heat conduction coefficient of the forming tool and the plate contact area in numerical simulation, and calculating the heat flow of the plate deformation area in real time by combining the contact heat conduction principle.
And (3) carrying out numerical simulation on the joule heating effect in the self-resistance electric heating incremental forming of the titanium alloy by calling an ABAQUS-VUINTER user subroutine in finite element software, comparing the numerical simulation with a test result to know that the temperature distribution is consistent, and controlling the error of the highest temperature within 5%. Meanwhile, fig. 2 shows an error analysis of the stable simulated temperature of the deformation region after the current acts, and the stable temperatures of the first five layers of four quadrant points of the forming region are respectively acquired, wherein 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.
And selecting a better numerical simulation result, obtaining reasonable configuration of forming process parameters (forming tool diameter, pressing quantity, feeding speed and current intensity), further converting a linear code of a numerical simulation track into a CNC code which can be identified by forming equipment, and finally transmitting the data into the forming equipment, thereby realizing rapid and intelligent manufacturing of the titanium alloy part.
In summary, 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, is more in line with the actual situation, has more accurate result, adopts the user subprogram of the display algorithm to secondarily develop the software, improves the usability, the universality and the reliability of the finite element software, combines the numerical simulation result with the forming equipment, realizes the rapid intelligent manufacture of the light alloy material, provides an intelligent manufacturing method for researching the electric auxiliary processing technology of other materials, and expands the flexibility of the technology
In the description of the present invention, it should be understood that the orientation or positional relationship indicated is based on the orientation or positional relationship shown in the drawings, and is merely for convenience in describing the present invention and simplifying the description, and does not indicate or imply that the apparatus or element referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention.
In the present invention, unless explicitly specified and defined otherwise, for example, it may be fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; either directly or indirectly through intermediaries, or in communication with each other or in interaction with each other, unless explicitly defined otherwise, the meaning of the terms described above in this application will be understood by those of ordinary skill in the art in view of the specific circumstances.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (1)
1. The self-resistance electric heating intelligent incremental forming method is characterized by comprising the following steps of:
step A: defining a volume change rate model dV/dt of the deformation region;
and (B) step (B): defining equivalent resistance of deformation region, i.e. resistance R of deformation region material according to circuit characteristics of contact region in self-resistance electric heating progressive forming s And contact resistance R j ；
Step C: defining an instantaneous Joule heat model dQ and an equivalent contact heat conduction coefficient model K of the deformation region according to the Joule heat phenomenon of the deformation region;
step D: the model dV/dt obtained in the step A and the model R obtained in the step B are processed through finite element software s And R is j C, substituting the obtained models dQ and K into a subroutine ABAQUS-VUINTER to accurately simulate the Joule heating effect of the contact area of the forming tool and the plate;
step E: inputting the technological parameters obtained by numerical simulation into processing equipment so as to realize the rapid forming of the parts;
in step B, resistance R of the deformation zone material s And contact resistance R j Taking the forming temperature as an internal variable; r is R s And R is j As shown in the formula (2) and the formula (3), respectively:
wherein ρ is s (T) and H (T) are respectively the resistivity and the hardness which are temperature dependent, R j (T r ) And H (T) r ) Respectively the contact resistance and the hardness of the material at room temperature, t g The material thickness is the deformation area;
in the step C, the transient joule heating model dQ and the equivalent contact heat conduction coefficient model K of the deformed region are shown in the following formulas (4) and (5), respectively:
dQ＝I 2 ·(R s +R j )·dt (4)
wherein I is the current intensity, T T And T s The temperature of the forming tool and the initial temperature of the plate are respectively;
the specific process of the step D is as follows: and (3) adopting ABAQUS software to obtain the model dV/dt obtained in the step A and the model R obtained in the step B s And R is j Substituting the models dQ and K obtained in the step C into a user subroutine ABAQUS-VUINTER, simulating the Joule heating effect of the contact area of the forming tool and the plate, comparing the simulated Joule heating effect with a test result, analyzing errors, and verifying the accuracy of a numerical simulation method;
the specific process of the step E is as follows: and (3) inputting the forming technological parameters and CNC codes obtained by numerical simulation into forming equipment, and rapidly setting forming tools, pressing quantity, feeding speed, current intensity and processing track in the forming process, so as to realize rapid and intelligent manufacturing of the parts.
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| CN202011177416.2A CN112439834B (en) | 2020-10-29 | 2020-10-29 | Self-resistance electric heating intelligent incremental forming method |
| PCT/CN2021/119197 WO2022089091A1 (en) | 2020-10-29 | 2021-09-18 | Self-resistive electric heating smart incremental forming method and system |
| ZA2021/08330A ZA202108330B (en) | 2020-10-29 | 2021-10-28 | Numerical control incremental forming method based on self-resistance electric heating and intelligent algorithm |
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| CN101318203A (en) * | 2008-06-24 | 2008-12-10 | 南京航空航天大学 | Electrical heating numerical control incremental forming processing method and device for plate |
| CN204074865U (en) * | 2014-07-29 | 2015-01-07 | 青岛理工大学 | The plate progressive molding device of hydraulic pressure support and auxiliary heating |
| CN104259303B (en) * | 2014-08-04 | 2015-12-09 | 安徽工业大学 | The progressive molding method of the outer local heat plate of a kind of processing stand |
| CN105033016B (en) * | 2015-07-13 | 2017-06-13 | 山东大学（威海） | Magnesium alloy sheet Electroplastic progressive molding method |
| CN105710205B (en) * | 2016-04-06 | 2017-09-05 | 北京航空航天大学 | Plate is overall from resistance heating progressive molding device |
| CN107413917B (en) * | 2017-07-05 | 2018-04-24 | 华中科技大学 | A kind of large-scale metal sheet electromagnetism progressive molding method based on plate face control shape |
| CN107999639A (en) * | 2017-12-11 | 2018-05-08 | 南京航空航天大学 | From resistance electrical heating progressive molding heater circuit intelligently connecting or disconnecting device |
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| US20220118501A1 (en) * | 2019-02-14 | 2022-04-21 | Northwestern University | In-Situ Springback Compensation In Incremental Sheet Forming |
| CN111069439B (en) * | 2019-11-28 | 2021-09-07 | 北京卫星制造厂有限公司 | Self-resistance heating incremental forming device and forming method |
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