CN115620842A - Staged electromagnetic heating simulation forming method for three-composite rivet - Google Patents
Staged electromagnetic heating simulation forming method for three-composite rivet Download PDFInfo
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Abstract
The invention discloses a staged electromagnetic heating simulation forming method for a three-composite rivet, which comprises the following steps: (1) a data acquisition stage; (2) Establishing a geometric model of a three-composite pre-heading ball-top composite section, a three-composite pre-heading ball bottom section, a three-composite pre-heading ball and a three-composite rivet; (3) The file format of the geometric model is converted (4), and the top of the three-composite pre-heading ball is subjected to analog simulation in the composite pre-heading ball forming stage; (5) finite element analysis in the three-composite pre-heading ball forming stage; (6) Finite element analysis is carried out in the electromagnetic heating forming stage of the three composite rivets; and (7) carrying out post-processing analysis on the finite element results in the steps (5) and (6), wherein the method has the advantages that: to the mound ball staged mound thick shaping in advance of three complex, can effective control mound ball deflection in advance, utilize electromagnetic heating technique fine solution cold heading shaping to the not enough of material bringing simultaneously, make rivet shaping quality have great improvement, practice thrift a large amount of engineering personnel time when guaranteeing the simulation result accuracy, improved simulation job's efficiency greatly.
Description
Technical Field
The invention belongs to the field of rivet forming finite element simulation, and particularly relates to a staged electromagnetic heating simulation forming method for a three-composite rivet.
Background
Electrical contacts are often found in household appliances, power systems, aerospace and other devices, and are mainly classified into the following three categories: fixed electrical contacts, such as electrical connectors, that rely on two contacts for electrical signal transmission; sliding electrical contact for electrical signal transmission by means of sliding contact of two contacts, such as electric brushes and roller contacts; the connection and disconnection of two contacts are used to realize the separable electric contact of connection and disconnection of the circuit, such as the contact of various switching appliances. Physical phenomena often occur during the electrical contact process, especially during the separable electrical contact process, such as increased contact resistance, arcing erosion of the contact surfaces, fusion welding, abrasion, material transfer, etc. With the development of social science and technology and application, higher requirements are put forward on the relevant performance of the selected electric contact material.
Rivet-type electric contact materials have been widely used in various switch fields because of their excellent characteristics combined with silver and other additives. Because the plastic processing process of rivet metal materials is complex, the traditional method can not meet the forming stress analysis deeply, and the introduction of finite elements can accurately simulate the forming process and the stress state of the materials.
Through retrieval, the related prior art of simulation for rivet products at present is as follows:
(1) Chinese patent CN111898291A, a method for predicting continuous riveting deformation of large wall panel based on substructure; the scheme is based on Abaqus software and is prepared by the following steps: the method comprises the steps of establishing a single-nail riveting finite element model → setting material properties of parts → pre-assembling the parts → performing simulation analysis and parameter setting → simulating → establishing a substructure simulation model and calculating → establishing a multi-nail wall plate riveting model → predicting deformation.
(2) The literature "season fly: the scheme of the document adopts Deform-3D finite element simulation software, and the preparation process comprises the following steps: establishing a low-pressure rotor steel model → setting parameters → obtaining results and analysis, wherein the part of the text simulates the down-pressing movement of a hydraulic press, and simultaneously finishes the twisting and upsetting of the forge piece, so that the quality of the whole forge piece after forging is influenced by different height-diameter ratios, friction factors, down-pressing speeds and twisting angles.
(3) The document "bang: a simulation study of a rivet-free connection forming process of heterogeneous materials, namely a simulation study of a rivet-free connection forming process of steel and aluminum by using finite element analysis software Abaqus, wherein the simulation study comprises the following preparation processes: geometric model establishment → parameter setting → molding result analysis → impact research of stamping speed on mechanical properties of a joint → electromagnetic riveting process test → conclusion, the research of the method finds that selecting 2000mm/s aiming at the die speed of the model can obtain better mechanical properties of rivet-free riveting on the premise of ensuring resilience as much as possible.
However, the above documents cannot perform analog simulation on the forming process of the three-composite rivet, and the traditional pre-heading ball forming of the three-composite rivet is one-step forming, which is very likely to cause the problems of insufficient bonding strength between material sections, uneven stress and the like, and therefore, needs to be solved and improved.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a three-composite rivet step-type electromagnetic heating simulation forming method, which can effectively control the deformation amount of a pre-upsetting ball and solve the problem of forming quality reduction caused by gradual deterioration of the effective cold plasticity for the three-composite pre-upsetting ball step-type upsetting forming.
In order to realize the purpose, the technical scheme of the invention comprises the following steps:
step (1), in a data acquisition stage, acquiring a die required for simulation and geometric dimensions of a pre-heading ball top composite material section and a three-composite pre-heading ball in the three-composite rivet through an actual three-composite rivet forming process, and simultaneously acquiring dimensions of a three-composite pre-heading ball bottom material section, an overall dimension of the three-composite pre-heading ball and a size of the three-composite rivet; the three-composite pre-heading ball top composite section and the three-composite pre-heading ball bottom section both comprise a silver metal oxide section (AgMeO) and a metal matrix section (such as Cu);
step (2), in the pretreatment stage, according to the actual geometric dimension in the step (1), establishing a geometric model for forming a top composite material section (AgMeO and Cu material section), a bottom material section (AgMeO/Cu), an integral triple composite pre-pier ball and a triple composite rivet of the triple composite pre-pier ball;
step (3), in the intermediate conversion transition stage, the format of the geometric model file is converted;
step (4), in a three-composite pre-heading ball-top composite pre-heading ball molding stage, introducing a composite material section (AgMeO and Cu) model, setting the number of simulation molds, controlling the stroke of the pre-heading ball mold, respectively defining material attributes, respectively carrying out grid division on the AgMeO and Cu material sections, and carrying out analog simulation;
step (5), in the three-composite pre-heading ball forming stage, importing AgMeO/Cu material sections at the bottoms of the three-composite pre-heading balls and the composite pre-heading ball simulation result in the step (4) into a three-composite pre-heading ball integral forming geometric model, carrying out different grid type repartitioning on the simulation result in the step (4) and the AgMeO/Cu material sections at the bottoms of the three-composite pre-heading balls, controlling the stroke of a pre-heading ball mold, and carrying out finite element analysis;
step (6), in the three-composite rivet electromagnetic heating forming stage, the type of a material forming module is changed, a three-composite rivet forming die and the three-composite pre-heading ball simulation result in the step (5) are led in, different grid types are subdivided on the simulation result in the step (5), the stroke of the rivet die is controlled, and finite element analysis is carried out;
and (7) carrying out post-processing analysis on the finite element results in the steps (5) and (6).
In the step (1), the data acquisition is the actual production data of the three-composite rivet, the data is the corrected average value, and the size sources of the three-composite pre-heading ball and the upper and lower dies of the rivet are all standard drawings;
when the geometric model is established in the pretreatment stage in the step (2), the three-dimensional CAD software can be Solidworks, autoCAD and the like, and the CAE software with the modeling function can be Abaqus, deform, simufact forming and the like.
Assembling the three-composite pre-heading ball-top composite material section and the upper and lower forming dies thereof in the pretreatment stage in the step (2), aligning the upper and lower dies by using tools such as Solidworks or CAD (computer-aided design), and adjusting the positions of the dies and the tools;
assembling the three-composite integral pre-heading ball material section and the upper and lower forming dies thereof in the pretreatment stage in the step (2), aligning the upper and lower dies by using tools such as Solidworks or CAD (computer aided design) and the like, and adjusting the positions of the dies and the tools;
in the STEP (3), the assembled SLDPRT file is converted into a STEP or STL file, and the three-dimensional CAD conversion software can be Solidworks, autoCAD and the like;
selecting a cold forming-upsetting forming mode in the step (4), and setting the number of the dies to be 4;
in the step (4), the upper and lower moulds of the pre-heading ball, the AgMeO and the Cu material section can be led in through CAD, and the material section can be drawn automatically through the basic shape function of the simulation software and can be adjusted in size freely;
selecting one of the dies, changing the type and attribute of the die, and inserting AgMeO or Cu material sections after the setting is finished;
manually or automatically positioning and matching the upper die and the lower die with the material section in the step (4), wherein the positioning and matching software comprises Simufect forming, deform or Ansys and the like;
in the step (4), agMeO and Cu material section upsetting is simulated by setting analysis parameters, wherein the analysis parameters comprise chemical components, mechanical properties, rheological curves, electromagnetic properties and the like of the material;
setting necessary conditions of the material section, the initial temperature of the die, the ambient temperature, the friction force between the dies, the die pressure and the like in the step (4);
carrying out finite element meshing on AgMeO and Cu material sections according to the actual required quantity in the step (4), wherein two material section mesh generators are set to be hexahedron molding, and the mesh type is set to be Hexmesh;
setting parameters such as stroke process, stroke speed, termination criterion and the like of the main mold in the molding process; carrying out finite element analysis after the setting is finished;
selecting a cold forming-upsetting forming mode from the forming modes in the step (5), wherein the number of the dies is 5;
step (5) leading the finite element analysis result after the post-processing of the step (4), the AgMeO/Cu material section at the bottom of the triple composite pre-heading ball, and the upper and lower dies required by the molding into a simulation project;
in the step (5), comprehensive positioning matching is carried out on the upper die and the lower die of the three composite pre-pier ball, the AgMeO and Cu composite material section in the step (5) and the AgMeO/Cu material section at the bottom of the three composite pre-pier ball, and positioning matching software comprises Simufact forming, solidworks and the like;
in the step (5), heading simulation is carried out on the AgMeO and Cu pre-heading balls and AgMeO/Cu material sections at the bottoms of the three composite pre-heading balls in the step (4) again by setting analysis parameters, wherein the analysis parameters comprise chemical components, mechanical properties, rheological curves and the like of the material;
setting necessary conditions of initial temperature, ambient temperature, friction force between moulds, mould pressure and the like of three parts of material moulds of the composite AgMeO and Cu pre-heading ball and the AgMeO/Cu section at the bottom of the three composite pre-heading balls in the step (4);
in the step (5), grid repartitioning is carried out on the AgMeO and Cu pre-heading balls and the AgMeO/Cu material sections at the bottoms of the three composite pre-heading balls in the step (4), the types of grid generators are specified to be tetrahedrons and hexahedrons, and the types of grids are Hexmesh or Tetmesh;
setting parameters such as stroke process, stroke speed, termination criterion and the like of the main mold in the three-composite pre-heading ball forming process; and 3D finite element analysis is carried out after the setting is finished.
Selecting a hot forging forming-upsetting forming mode in the step (6), and selecting a limited unit by a solver, wherein the number of the dies is 5;
step (6) guiding the finite element analysis result processed in the step (5) and the upper and lower dies of the three-composite rivet into simulation forming;
in the step (6), comprehensive positioning and matching of the upper and lower molds of the three-composite rivet and the three-composite pre-pier ball in the step (5) are carried out, and positioning and matching software comprises Simufact forming, solidworks and the like;
in the step (6), the initial molding temperature of the mold is selected to be 20-100 ℃, the type of the material mold is set to be a rigid mold with heat transfer, and the conduction coefficient between the mold and the environment is set to be 10-30W/(M) 2 K); the emissivity of the material to the environment is 0.1-0.5;
in the step (6), the initial temperature of the three-composite pre-pier ball forming is selected to be 100-800 ℃, and the conductivity coefficient of the three-composite pre-pier ball and the environment is set to be 20-50W/(M) 2 K); the emissivity to the environment is 0.1-0.5;
in the step (6), rivet forming simulation is carried out on the triple composite pre-heading ball in the step (5) by setting analysis parameters, wherein the analysis parameters comprise chemical components, mechanical properties, rheological curves and the like of the material;
setting necessary conditions such as initial temperature, environment temperature, friction force between the dies, die pressure and the like of the upper die and the lower die of the rivet in the step (6);
in the step (6), grid repartitioning is carried out on each position of the three composite pre-heading balls in the step (5), the type of the grid generator is specified to be a surface grid, and the type of the grid is specified to be a triangle;
setting parameters such as stroke process, stroke speed, termination criterion and the like of the main mold in the three-composite pre-heading ball forming process; and 3D finite element analysis is carried out after the setting is finished.
In the step (7), post-processing analysis is respectively carried out on the finite element analysis results in the step (5) and the step (6), and the post-processing analysis mainly comprises the stress strain among three composite sections and three composite pre-pier balls, the influence of the height of the pre-pier balls on rivet forming, the stroke among dies, the pressure applied to the dies and the like.
The application has the beneficial effects that: the method provides a brand-new forming and stress analysis mode for the three-composite rivet, can effectively control the deformation of the pre-pier ball for the three-composite pre-pier ball stage type upsetting forming, is convenient for analyzing the forming stress condition of the material at each stage, is beneficial to providing a more stable process for the three-composite rivet forming, and can quickly predict the stress-strain parameters and the material flow condition of the three-composite rivet at different stages on the production basis. In addition, because the cold plasticity of the rivet is gradually worsened in the pre-upsetting process of the pre-upsetting ball, the strain rate is lower, and the cold deformation is gradually difficult, the electromagnetic heating technology well solves the defects in the cold heading forming process, so that the forming quality of the rivet is greatly improved. The two modes can provide a certain reference basis for the actual deformation control of the rivet, and greatly save time of engineering personnel while ensuring the accuracy of a simulation result.
The method provides a brand-new three-composite rivet staged forming stress analysis mode. The method has the advantages that the deformation of the pre-upsetting ball can be effectively controlled in the step-type upsetting forming of the three-composite pre-upsetting ball, the stress condition of the forming material in each step can be conveniently analyzed, a more stable process can be provided for the forming of the three-composite rivet, the stress-strain parameters and the material flow condition of the three-composite rivet in different steps can be rapidly predicted on the basis of production, and a certain reference basis is provided for the actual deformation control of the rivet; meanwhile, the defects brought by cold heading forming to materials are well solved by utilizing an electromagnetic heating technology, so that the forming quality of the rivet is greatly improved, the accuracy of a simulation result is ensured, meanwhile, the time of engineering personnel is greatly saved, and the efficiency of simulation work is greatly improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the prior art descriptions will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is within the scope of the present invention for those skilled in the art to obtain other drawings based on the drawings without inventive labor.
FIG. 1 is a schematic view of the formation of a top composite pre-heading ball of a triple composite pre-heading ball;
FIG. 2 is a schematic diagram of the formation of a triple composite pre-heading ball;
FIG. 3 is a flow chart of the staged simulation forming of the triple composite rivet of the present invention.
Detailed Description
To make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in further detail with reference to the accompanying drawings.
Example one
The embodiment provides a staged electromagnetic heating simulation forming method for a three-composite rivet, which comprises the following specific steps:
step 1, in a data acquisition stage, acquiring geometric dimensions of a die required for simulation and pre-heading ball top composite material sections (AgMeO and Cu) and composite pre-heading balls (AgMeO and Cu) in three composite rivets through an actual three-composite rivet forming process, acquiring the AgMeO/Cu material section dimensions at the bottom of the three composite pre-heading balls and the overall dimensions of the three composite pre-heading balls, correcting and averaging data, and setting the three composite pre-heading balls and upper and lower dies of the rivets according to a standard drawing;
step 2, in a pretreatment stage, establishing a geometric model formed by three composite pre-heading balls, a top composite material section (AgMeO and Cu material sections), a bottom material section (AgMeO), an integral three composite pre-heading ball and three composite rivets by utilizing Solidworks modeling software according to the obtained actual geometric dimension; after the setting is finished, assembling, aligning and adjusting the position relation between the die and the tool to be contact are respectively carried out on the three composite pre-heading ball-top composite section, the integral three composite pre-heading ball, the three composite rivets and the corresponding upper die and the lower die by utilizing Solidworks;
STEP 3, in the intermediate conversion transition stage, converting the assembled SLDPRT file into a STEP file by utilizing Solidworks;
step 4, in the three-composite pre-heading ball-top composite pre-heading ball forming stage, the forming mode is cold forming-heading forming, and the number of the dies is set to be 4; leading in three composite pre-heading balls, namely an upper die and a lower die of the top composite pre-heading ball and AgMeO and Cu sections through CAD, and manually positioning and matching the upper die and the lower die of the pre-heading ball and the composite sections by using Simufact forming;
setting analysis parameters of AgMeO, wherein the chemical composition of the material is AgSnO 2 (15) A tensile strength of 312MPa, a Poisson ratio of 0.35, a Young's modulus of 270000MPa, and a density of 9.9g/cm 3 The resistivity is 2.2 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament; setting the analysis parameters of Cu, including the chemical composition of Cu, 205MPa of tensile strength, 0.3 of Poisson's ratio, 280000MPa of Young's modulus and 8.6g/cm of density 3 The resistivity is 2.3 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament;
setting AgSnO 2 The initial temperature of the Cu material section and the environment temperature are 20 ℃, the initial temperature of the die is 25 ℃, the friction force between the dies is 0.08, the friction force between the material sections is 0.10, and the pressure of the main die is a hydraulic press; after the setting is finished, the AgSnO is subjected to surface treatment according to the actual required quantity 2 And carrying out finite element meshing on the Cu material sections, wherein two material section mesh generators are set to be hexahedron-shaped, and the mesh type is Hexmesh; setting the stroke process of the main mould to be 0.3mm, the stroke speed to be 2mm/s and the termination criterion to be 100% in the forming process;
after the setting is finished, three-composite pre-heading ball-top composite pre-heading ball (AgSnO) 2 Cu) finite element analysis.
Step 5, in a three-composite pre-heading ball forming stage, cold forming-heading forming is selected as a forming mode, and the number of the dies is set to be 5; leading in three-composite pre-heading ball-top composite pre-heading ball (AgSnO) through existing result options 2 And Cu)And a three-composite pre-pier ball bottom material section (AgSnO) 2 ) (ii) a Manually positioning and matching the upper die and the lower die of the three composite pre-heading balls and the three material sections by using Simufact forming;
the parameters of the three-composite pre-heading ball and the top composite pre-heading ball are not changed any more, and only the parameters of the bottom material section of the three-composite pre-heading ball are set, wherein the parameters comprise that the tensile strength of the material is 300MPa, the Poisson ratio is 0.3, the Young modulus is 250000MPa, and the density is 9.89g/cm 3 The resistivity is 2.35 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament; the initial temperature of the material section and the ambient temperature are 20 ℃, the initial temperature of the die is 25 ℃, the friction force between the dies is 0.1, the friction force between the material sections is 0.2, and the pressure of the main die is a hydraulic machine; after the setting is finished, the AgSnO is subjected to the treatment according to the actual required quantity 2 The material section is subjected to finite element meshing, a material section mesh generator is set to be hexahedron-shaped, and the mesh type is Hexmesh; setting the stroke process of the main mould to be 0.5mm, the stroke speed to be 3mm/s and the termination criterion to be 100% in the forming process;
after the setting is finished, three-composite pre-pier ball (AgSnO) 2 -Cu-AgSnO 2 ) And (4) finite element analysis.
Step 6, in the three-composite-rivet electromagnetic heating forming stage, the forming mode is hot forging forming-upsetting forming, a solver selects limited units, and the number of dies is 5; guiding the finite element analysis result after the step 5 and the upper and lower dies of the three-composite rivet into simulation forming; the upper and lower dies of the three-composite rivet and the three-composite pre-heading ball (AgSnO) in the step 5 are added 2 -Cu-AgSnO 2 ) Carrying out comprehensive positioning matching, wherein the positioning matching software comprises Simufact forming, solidworks and the like; the initial temperature of the mold forming is selected to be 20 ℃, the type of the mold of the material is set to be a rigid mold with heat transfer, and the conduction coefficient of the mold and the environment is set to be 10W/(M) 2 K); the emissivity to the environment is 0.1; the initial temperature of the three-composite pre-heading ball is 300 ℃, and the conductivity coefficient of the three-composite pre-heading ball and the environment is set to be 50W/(M) 2 K); the emissivity to the environment was 0.2.
In addition to this parameter, the setting is again the same as step 5AgSnO of the same 2 -Cu-AgSnO 2 The analysis parameters comprise chemical components, mechanical properties, rheological curves and the like of the material; after the setting is finished, agSnO is carried out 2 -Cu-AgSnO 2 And (4) carrying out electromagnetic heating finite element analysis on the three composite rivets.
And 7, carrying out post-processing analysis on the finite element results in the step 5 and the step 6, wherein the post-processing analysis mainly comprises the influence of parameters such as stress strain between the three composite sections and the three composite pre-pier balls, the pre-pier height, the stroke between the dies and the like on the electromagnetic heating forming of the three composite rivets.
The second embodiment:
a three-composite rivet staged electromagnetic heating simulation forming method comprises the following specific steps:
step 1, in a data acquisition stage, acquiring geometric dimensions of a die required for simulation and pre-heading ball top composite material sections (AgMeO and Cu) and composite pre-heading balls (AgMeO and Cu) in three composite rivets through an actual three-composite rivet forming process, acquiring the AgMeO/Cu material section dimensions at the bottom of the three composite pre-heading balls and the overall dimensions of the three composite pre-heading balls, correcting and averaging data, and setting the three composite pre-heading balls and upper and lower dies of the rivets according to a standard drawing;
step 2, in the pretreatment stage, according to the obtained actual geometric dimension, a Solidworks modeling software is utilized to establish a geometric model for forming three composite pre-heading balls, namely a top composite material section (AgMeO and Cu material sections), a bottom material section (Cu), an integral three composite pre-heading ball and three composite rivets; after the setting is finished, assembling, aligning and adjusting the position relation between the die and the tool to be contact are respectively carried out on the three composite pre-heading ball-top composite section, the integral three composite pre-heading ball, the three composite rivets and the corresponding upper die and the lower die by utilizing Solidworks;
STEP 3, in the intermediate conversion transition stage, converting the assembled SLDPRT file into a STEP file by utilizing Solidworks;
step 4, in a three-composite pre-heading ball-top composite pre-heading ball forming stage, selecting cold forming-heading forming in a forming mode, and setting the number of dies to be 4; leading in three composite pre-heading balls, namely an upper die and a lower die of the top composite pre-heading ball and AgMeO and Cu sections through CAD, and manually positioning and matching the upper die and the lower die of the pre-heading ball and the composite sections by using Deform;
setting analysis parameters of AgMeO, wherein the chemical composition of the AgSnO 2 (12) 300MPa tensile strength, 0.35 Poisson's ratio, 260000MPa Young's modulus, 9.5g/cm density 3 The resistivity is 2.5 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament; setting the analysis parameters of Cu, including the chemical components of Cu, tensile strength of 200Pa, poisson's ratio of 0.3, young's modulus of 280000MPa and density of 8.3g/cm 3 The resistivity is 2.3 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament;
setting AgSnO 2 And the initial temperature of the Cu material section, the ambient temperature of 20 ℃, the initial temperature of the die of 25 ℃, the frictional force between the dies of 0.1, the frictional force between the material sections of 0.10, and the pressure of the main die of the hydraulic press; after the setting is finished, the AgSnO is subjected to the treatment according to the actual required quantity 2 And carrying out finite element meshing on the Cu material sections, wherein the two material section mesh generators are arranged to be hexahedron-shaped, and the mesh type is Hexmesh; setting the stroke process of the main mould to be 0.5mm, the stroke speed to be 4mm/s and the termination criterion to be 98% in the forming process;
after the setting is finished, three-composite pre-heading ball-top composite pre-heading ball (Cu-AgSnO) 2 ) And (4) finite element analysis.
Step 5, in a three-composite pre-heading ball forming stage, cold forming-heading forming is selected as a forming mode, and the number of the dies is set to be 5; leading in three-composite pre-heading ball-top composite pre-heading ball (AgSnO) through existing result options 2 And Cu) and a three-composite pre-heading ball bottom material section (Cu); manually positioning and matching the upper die and the lower die of the three-composite pre-heading ball and the three material sections by using Deform;
the parameters of the three-composite pre-heading ball and the top composite pre-heading ball are not changed any more, and only the parameters of the Cu material section at the bottom of the three-composite pre-heading ball are set, wherein the parameters comprise that the tensile strength of the material is 200MPa, the Poisson ratio is 0.2, the Young modulus is 220000MPa, and the density is 8.4g/cm 3 The resistivity is 2.1 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament; the initial temperature of the material section and the ambient temperature are 25 ℃, and the initial temperature of the die isAt 25 ℃, the friction force between the dies is 0.1, the friction force between the material sections is 0.2, and the pressure of the main die is a hydraulic press; after the setting is finished, carrying out finite element meshing on the Cu material sections according to the actual required quantity, setting the material section mesh generator to be in tetrahedral forming, and setting the stroke process of the main mold to be 1mm, the stroke speed to be 5mm/s and the termination criterion to be 98% in the forming process;
after the setting is finished, three-composite pre-heading ball (Cu-AgSnO) 2 Cu) finite element analysis.
Step 6, in the three-composite-rivet electromagnetic heating forming stage, the forming mode is hot forging forming-upsetting forming, a solver selects a limited unit, and the number of dies is 5; guiding the finite element analysis result after the step 5 and the upper and lower dies of the three-composite rivet into simulation forming; the upper and lower dies of the three-composite rivet and the three-composite pre-heading ball (Cu-AgSnO) in the step 5 are placed 2 Cu) for comprehensive positioning matching, wherein positioning matching software comprises Simufact forming, solidworks and the like; the initial temperature of the mould forming is selected to be 30 ℃, the type of the mould of the material is set to be a rigid mould with heat transfer, and the conduction coefficient between the mould and the environment is set to be 25W/(M) 2 K); the emissivity to the environment is 0.4; the initial temperature of the three-composite pre-heading ball is 800 ℃, and the conductivity coefficient of the three-composite pre-heading ball and the environment is set to be 30W/(M) 2 K); the emissivity to the environment is 0.3.
In addition to this parameter, the same Cu-AgSnO as in step 5 was set again 2 -analytical parameters of Cu including chemical composition, mechanical properties, rheological profile, etc. of the material; after the setting is finished, carrying out Cu-AgSnO 2 -Cu triple composite rivet electromagnetic heating finite element analysis.
And 7, carrying out post-processing analysis on the finite element results in the step 5 and the step 6, wherein the post-processing analysis mainly comprises the influence of parameters such as stress strain among three composite sections and three composite pre-pier balls, pre-pier height, stroke among dies and the like on the forming of the three composite electromagnetic heating rivet.
Example three:
a three-composite rivet staged electromagnetic heating simulation forming method comprises the following specific steps:
step 1, in a data acquisition stage, acquiring geometric dimensions of a die required for simulation and pre-heading ball top composite material sections (AgMeO and Cu) and composite pre-heading balls (AgMeO and Cu) in three composite rivets through an actual three-composite rivet forming process, acquiring the AgMeO/Cu material section dimensions at the bottom of the three composite pre-heading balls and the overall dimensions of the three composite pre-heading balls, correcting and averaging data, and setting the three composite pre-heading balls and upper and lower dies of the rivets according to a standard drawing;
step 2, in a pretreatment stage, establishing a geometric model formed by three composite pre-heading balls, a top composite material section (AgMeO and Cu material sections), a bottom material section (AgMeO), an integral three composite pre-heading ball and three composite rivets by utilizing Solidworks modeling software according to the obtained actual geometric dimension; after the setting is finished, assembling, aligning and adjusting the position relation among the mould and the tool to be bonding by utilizing Solidworks to the three-composite pre-heading ball-top composite material section, the integral three-composite pre-heading ball, the three-composite rivet and the corresponding upper mould and lower mould;
STEP 3, in the intermediate conversion transition stage, converting the assembled SLDPRT file into a STEP file by utilizing Solidworks;
step 4, in the three-composite pre-heading ball-top composite pre-heading ball forming stage, the forming mode is cold forming-heading forming, and the number of the dies is set to be 4; leading in three composite pre-heading balls, namely an upper die and a lower die of the top composite pre-heading ball and AgMeO and Cu material sections through CAD, and manually positioning and matching the upper die and the lower die of the pre-heading ball and the composite material sections by using Ansys;
setting analysis parameters of AgMeO, wherein the chemical composition of the AgSnO 2 (20) 330MPa tensile strength, 0.35 Poisson's ratio, 290000MPa Young's modulus, 9.5g/cm density 3 The resistivity is 2.0 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament; setting the analysis parameters of Cu, including the chemical composition of Cu, the tensile strength of 210MPa, the Poisson ratio of 0.25, the Young modulus of 220000MPa and the density of 8.39g/cm 3 The resistivity is 2.45 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament;
setting AgSnO 2 And the initial temperature of the Cu material section and the ambient temperature are 30 DEG CThe initial temperature of the die is 35 ℃, the friction force between the dies is 0.1, the friction force between the material sections is 0.3, and the pressure of the main die is a crank rocker machine; after the setting is finished, the AgSnO is subjected to the treatment according to the actual required quantity 2 And carrying out finite element meshing on the Cu material sections, wherein two material section mesh generators are set to be shaped like a tetrahedron; setting the stroke process of the main mould to be 0.1mm, the stroke speed to be 1mm/s and the termination criterion to be 99% in the forming process;
after the setting is finished, three-composite pre-heading ball-top composite pre-heading ball (AgSnO) 2 Cu) finite element analysis.
Step 5, in the three-composite pre-heading ball forming stage, cold forming-heading forming is selected as a forming mode, and the number of the dies is set to be 5; leading in three-composite pre-heading ball-top composite pre-heading ball (AgSnO) through existing result options 2 Cu) and three-composite pre-heading ball bottom material section (AgSnO) 2 ) (ii) a Manually positioning and matching the upper and lower dies of the three-composite pre-heading ball and the three material sections by using Ansys;
the parameters of the three-composite pre-heading ball and the top composite pre-heading ball are not changed any more, and only the parameters of the bottom material section of the three-composite pre-heading ball are set, wherein the parameters comprise that the tensile strength of the material is 310MPa, the Poisson ratio is 0.2, the Young modulus is 230000MPa, and the density is 9.89g/cm 3 The resistivity is 2.33 mu omega cm, and the rheological curve is the stretching data of the actual extensometer to the filament; the initial temperature of the material section and the ambient temperature are 30 ℃, the initial temperature of the die is 35 ℃, the friction force between the dies is 0.1, the friction force between the material sections is 0.3, and the pressure of the main die is a hydraulic machine; after the setting is finished, the AgSnO is subjected to surface treatment according to the actual required quantity 2 The material section is subjected to finite element meshing, a material section mesh generator is set to be hexahedron-shaped, and the mesh type is set to be Hexmesh; setting the stroke process of the main mould to be 0.6mm, the stroke speed to be 3mm/s and the termination criterion to be 100 percent in the forming process;
after the setting is finished, three-composite pre-pier ball (AgSnO) 2 -Cu-AgSnO 2 ) And (4) finite element analysis.
Step 6, in the three-composite-rivet electromagnetic heating forming stage, the forming mode is hot forging forming-upsetting forming, and the solver is selectedThe number of the moulds is 5; guiding the finite element analysis result after the step 5 and the upper and lower dies of the three-composite rivet into simulation forming; combining the upper and lower dies of the three-composite rivet with the three-composite pre-pier ball (AgSnO) in the step 5 2 -Cu-AgSnO 2 ) Carrying out comprehensive positioning matching, wherein positioning matching software comprises Simufact forming, solidworks and the like; the initial temperature of the mould forming is selected to be 50 ℃, the type of the mould of the material is set to be a rigid mould with heat transfer, and the conduction coefficient between the mould and the environment is set to be 20W/(M) 2 K); the emissivity to the environment is 0.2; the initial temperature of the three-composite pre-heading ball is 500 ℃, and the conductivity coefficient of the three-composite pre-heading ball and the environment is set to be 40W/(M) 2 K); the emissivity to the environment is 0.1.
Except for this parameter, the same AgSnO as in step 5 was set again 2 -Cu-AgSnO 2 The analysis parameter values of (1) comprise chemical compositions, mechanical properties, rheological curves and the like of the material; after the setting is finished, agSnO is carried out 2 -Cu-AgSnO 2 And (4) carrying out electromagnetic heating finite element analysis on the three composite rivets.
And 7, carrying out post-processing analysis on the finite element results in the step 5 and the step 6, wherein the post-processing analysis mainly comprises the influence of parameters such as stress strain between the three composite sections and the three composite pre-pier balls, the pre-pier height, the stroke between the dies and the like on the electromagnetic heating forming of the three composite rivets.
The above description is only for the purpose of illustrating the technical solutions of the present invention, and not for the purpose of limiting the scope of the present invention, and the simple modifications or equivalent substitutions of the technical solutions of the present invention by those skilled in the art can be made without departing from the spirit and scope of the technical solutions of the present invention.
By adopting the technical scheme, the invention can obtain the following technical effects:
(1) Provides a brand-new forming and stress analysis mode for the three-composite rivet. For the staged upsetting forming of the three-composite pre-upsetting ball, the deformation of the pre-upsetting ball can be effectively controlled, the forming stress condition of the material at each stage can be conveniently analyzed, a more stable process can be provided for the forming of the three-composite rivet, and meanwhile, the stress-strain parameters and the material flow condition of the three-composite rivet at different stages can be rapidly predicted on the basis of production;
(2) Because the cold plasticity of the rivet is gradually reduced in the upsetting process of the pre-upsetting ball, the strain rate is lower, and the cold deformation is gradually difficult, the electromagnetic heating technology well solves the defects in the cold upsetting forming process, so that the forming quality of the rivet is greatly improved;
(3) The grid division types are different, the difficulty of simulation operation of the three-composite rivet is relieved to a great extent, the phenomenon of error or stop in the operation process is effectively avoided, and the actual composite rivet forming process can be restored more truly;
(4) The method effectively reduces the production cost while ensuring the accuracy of the result, is suitable for simulation of various three-composite rivets, and has the functions of economy, high efficiency, rapidness and accurate simulation analysis.
Further, while operations of the methods of the invention are depicted in the drawings in a particular order, this does not require or imply that these operations must be performed in this particular order, or that all of the illustrated operations must be performed, to achieve desirable results. Rather, the steps depicted in the flowcharts may change the order of execution. Additionally or alternatively, certain steps may be omitted, multiple steps combined into one step execution, and/or one step broken down into multiple step executions. It should also be noted that the features and functions of two or more devices according to the invention may be embodied in one device. Conversely, the features and functions of one apparatus described above may be further divided into embodiments by a plurality of apparatuses.
While the invention has been described with reference to several particular embodiments, it is to be understood that the invention is not limited to the specific embodiments disclosed. The invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Claims (6)
1. A three-composite rivet staged electromagnetic heating simulation forming method is characterized by comprising the following steps:
(1) A data acquisition stage: acquiring a die required by simulation and geometric dimensions of a top composite section and a bottom composite section of a triple composite pre-heading ball and the triple composite pre-heading ball through an actual forming process of the triple composite rivet, and simultaneously acquiring the dimensions of the bottom section of the triple composite pre-heading ball, the overall dimension of the triple composite pre-heading ball and the dimension of the triple composite rivet, wherein the top composite section of the triple composite pre-heading ball and the bottom section of the triple composite pre-heading ball comprise a silver metal oxide material section and a metal matrix material section;
(2) A pretreatment stage: according to the geometric dimension of the step (1), establishing a geometric model for forming a top composite material section, a bottom material section, a whole body of the three-composite pre-heading ball and three-composite rivets in three-dimensional software;
(3) Intermediate conversion transition stage: converting the file format of the geometric model;
(4) In the top composite pre-heading ball forming stage of the three-composite pre-heading ball, introducing a geometric model of a top composite material section of the three-composite pre-heading ball, setting the number of simulation molds, controlling the stroke of the pre-heading ball mold, respectively defining material properties, respectively carrying out meshing on a silver metal oxide material section and a metal matrix material section in the top composite material section of the three-composite pre-heading ball, and carrying out analog simulation;
(5) In the three-composite pre-heading ball forming stage, the three-composite pre-heading ball bottom material section geometric model and the simulation result in the step (4) are led into the three-composite pre-heading ball integral geometric model, the simulation result in the step (4) and the three-composite pre-heading ball bottom material section are subjected to different grid type re-division, the pre-heading ball die stroke is controlled, and finite element analysis simulation is carried out;
(6) In the three-composite-rivet electromagnetic heating forming stage, the type of a material forming module is changed, a geometric model of the three-composite-rivet forming module and a three-composite pre-heading ball simulation result in the step (5) are introduced, different grid types are subdivided on the simulation result in the step (5), the stroke of a rivet die is controlled, and finite element analysis simulation is carried out;
(7) And (6) carrying out post-processing analysis on the finite element results in the step (5) and the step (6).
2. The method for the staged electromagnetic heating simulated forming of the triple composite rivet according to claim 1, characterized in that: when the geometric model is established in the step (2), the three-dimensional CAD software is selected from Solidworks and AutoCAD, and the CAE software with the modeling function is selected from Abaqus, deform or Simufact forming.
3. The method for the staged electromagnetic heating simulated forming of the triple composite rivet according to claim 1, characterized in that: and (4) carrying out finite element meshing on the silver metal oxide material section and the metal matrix material section of the composite material section at the top of the three-composite pre-heading ball according to the actual required quantity, wherein the two material section mesh generators are formed into hexahedrons, and the mesh type is Hexmesh.
4. The method for the staged electromagnetic heating simulated forming of the triple composite rivet according to claim 1, characterized in that: and (5) selecting upsetting forming in the hot forging forming in the forming mode of the step (6), and selecting a limited unit by a solver.
5. The method for the staged electromagnetic heating simulated forming of the triple composite rivet according to claim 2, characterized in that: in the step (6), the initial molding temperature of the mold is selected to be 20-100 ℃, the mold type of the material is set to be a rigid mold with heat transfer, and the conduction coefficient of the mold and the environment is set to be 10-30W/(M) 2 K); the emissivity of the material to the environment is 0.1-0.5.
6. The method for the staged electromagnetic heating simulated forming of the triple composite rivet according to claim 3, characterized in that: in the step (6), the initial temperature of the three-composite pre-pier ball forming is selected to be 100-800 ℃, and the conductivity coefficient of the three-composite pre-pier ball and the environment is set to be 20-50W/(M) 2 K); the emissivity of the material to the environment is 0.1-0.5.
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