板料三维成形过程的有限元数值模拟

基于有限变形理论建立了三维金属板料成形过程的刚塑性有限元数学模拟,该数学模型采用物质坐标系中的Ｕｐｄａｔｅ－Ｌａｇｒａｎｇｅ描述,等向强化假设,考虑了板料的厚向异性,对于金属板料与模具有摩擦采用近似的库仑摩擦定律以改善计算的收敛性。为简经计算采用薄膜单元,并根据此模型编制程序。     

金属板料拉延二次成形的有限元法模拟

建立了二次拉延成形加工的有限元分析计算模型;采用一次成形-回弹计算-二次成形的连续计算过程模拟了实际加工过程;有限元计算采用动力显式计算程序MSC/DYTRAN;用主从面（master surface-slave surface)模型定义板料和模具的接触,摩擦力用库仑定律计算;利用动力松弛法对成形过程中的回弹进行了计算。模拟结果和实际零件比较,证明模型合理,自满稳定,结果可靠,具有良好的应用价值。     

正交各向异性金属板料的成形极限

1993年希尔提出了一个适用于正交各向异性材料的屈服准则,该文运用该屈服准则和马辛尼克-库祖斯基假设,建立了能够确定正交各向异性金属板料成形极限的控制方程并数值求解,分析了不同材料参数对成形极限图的影响.     

双金属板拉延成形的有限元分析

双金属板拉延成形同时包含几何非线性、塑性、接触、摩擦以及双金属板中组元金属力学性能差异等多种复杂因素。组元金属之间不均匀的塑性变形是导致组元金属在拉延过程中产生缺陷的主要根源。本文基于刚塑性有限元方法，对双金属板的拉延成形过程进行了有限元分析，揭示了组元金属的等效应变分布规律和厚向应变分布规律。本文的研究方法和结论可以为工艺参数的合理选择和优化提供参考和依据。     

粘塑性材料成形过程的有限元分析

为了确定大型铝机轮等温锻造的变形力及揭示轮缘处形成折叠的原因,本文用刚一粘塑性有限元法对模拟件的成形过程进行了全面数值模拟。模拟计算和实验结果表明,有限元确定的等温锻造过程的变形力,可作为选择设备吨位的依据,根据刚-粘塑性有限元法所预测的金属流动规律,发现零件的形状很大程度上决定了轮缘处容易形成折叠。适当改进模具结构和改善润滑条件,有助于避免折叠缺陷的产生。     

钢丝绳捻制成形的空间几何模型与有限元分析

根据钢丝绳捻制成形原理，在考虑钢丝绳空间几何形状的基础上，建立了引入自扭转系数时钢丝绳的几何结构计算模型和钢丝绳捻制成形有限元计算边界条件模型。进而编制了相应的有限元建模程序，生成可被ANSYS直接调用的数据文件。分析了钢丝绳一次捻制和二次捻制的加工应力应变变化情况，并讨论了自扭转系数对加工应力应变的影响。     

金属板条在圆柱形模中弯曲成形的大变形有限元分析

本文采用大变形弹塑性有限元法对金属板条在柱形模中的压弯成形过程进行了数值模拟，并与实验进行了比较，首先给出了纠正的拉格朗日有限元公式和基于弹塑性乘法分解的超弹性塑性本构关系。对接触摩擦问题的处理采用了罚函数法。通过对数值结果的分析得出了些对弯曲工艺的设计有指导价值的结论。     

基于有限元的板料拉延成形质量评价准则及工艺参数优化研究

近年来,以有限元分析工具并结合优化算法来提高板料的成形性能已成为新的研究热点.然而,如何建立合理的板料成形质量评价准则以形成日标函数,从而量化冲压件的成形质量是其关键技术之一.该文在研究国内外现有的各种评价拉裂和起皱缺陷准则的基础上,提出了指数加权评价准则,该准则量化了单元落在成形极限图上不同区域和离安全区域距离远近不同分别对拉裂和起皱权值贡献的差异.结合方形盒标准考题验证了提出的评价准则的合理性.将该质量评价准则应用到了一个实际零件的成形优化研究中,优化的结果显著的提高了板料的成形性能.     

一种适用于板料成形过程分析的自适应有限元方法

本文主要讨论在板料成形过程的动态显式有限元分析中,有限元网格的丙分割技术。单元为四节点壳单元,板料的材料特性假定满足Ｈｉｌｌ各向异性的弹塑性准则,采用自适应ｈ－方案,通过细化和聚合单元调整网格的疏密,模具被假定为由刚性小平面组成,与同一单元的节点发生接触处的模具表面的法线之间的夹角作为单元再分的判据。通过对方表盒冲压成形过程的计算,说明该方法是有效的。     

覆盖件冲压仿真中的网格形态优化技术

覆盖件冲压仿真计算模型中网格密度分布的合理性与网格单元形态的优劣,对仿真结果的准确性有很大的影响.提出了一种改进的全四边形网格细分方法,使网格的密度分布适于覆盖件冲压分析计算要求,可保证细分后网格的协调性,并将算法推广以处理非结构化四边形网格和三角形四边形混合网格的细分.提出的网格细分策略,有助于提高细分后网格的质量.提出了适用于细分后四边形网格和非结构四边形网格的拓扑形态优化操作,可有效的提高网格模型的形态质量.     

板材多点成形过程的有限元分析

多点成形过程采用静力隐式格式进行数值模拟是比较合适的。本文建立了用于多点成形过程分析的静力隐式弹塑性大变形有限元方法 ,给出了对稳定迭代收敛过程效果较好的板壳有限单元模型、处理多点不连续接触边界的接触单元方法以及增量变形过程中应力及塑性应变计算的多步回映计算方法。基于这些方法编制了计算软件 ,应用该软件进行了矩形板的液压胀形过程及球形模具拉伸成形过程的有限元分析 ,数值计算结果与典型的实验结果及计算结果吻合很好。最后给出了球形、圆柱形目标形状的实际多点成形过程的数值模拟结果。     

三维板料成形过程的显式有限元分析

本文采用基于随动坐标系的假定应变域壳单元及显式有限元格式求解三维板料成形问题。板材料服从Ｈｉｌ各向异性弹塑性准则，板料与模具之间的接触界面由主仆面接触搜寻法处理，接触力由罚参数法计算。文中给出了几个三维成形过程的计算实例。数值算例表明，本文方法具有较高的计算精度和计算效率，可在微机上分析中等复杂程度的成形过程     

A non-associated constitutive model with mixed iso-kinematic hardening for finite element simulation of sheet metal forming

In this paper an anisotropic material model based on non-associated flow rule and mixed isotropic–kinematic hardening was developed and implemented into a user-defined material (UMAT) subroutine for the commercial finite element code ABAQUS. Both yield function and plastic potential were defined in the form of Hill’s [Hill, R., 1948. A theory of the yielding and plastic flow of anisotropic metals. Proc. R. Soc. Lond. A 193, 281–297] quadratic anisotropic function, where the coefficients for the yield function were determined from the yield stresses in different material orientations, and those of the plastic potential were determined from the r-values in different directions. Isotropic hardening follows a nonlinear behavior, generally in the power law form for most grades of steel and the exponential law form for aluminum alloys. Also, a kinematic hardening law was implemented to account for cyclic loading effects. The evolution of the backstress tensor was modeled based on the nonlinear kinematic hardening theory (Armstrong–Frederick formulation). Computational plasticity equations were then formulated by using a return-mapping algorithm to integrate the stress over each time increment. Either explicit or implicit time integration schemes can be used for this model. Finally, the implemented material model was utilized to simulate two sheet metal forming processes: the cup drawing of AA2090-T3, and the springback of the channel drawing of two sheet materials (DP600 and AA6022-T43). Experimental cyclic shear tests were carried out in order to determine the cyclic stress–strain behavior and the Bauschinger ratio. The in-plane anisotropy (r-value and yield stress directionalities) of these sheet materials was also compared with the results of numerical simulations using the non-associated model. These results showed that this non-associated, mixed hardening model significantly improves the prediction of earing in the cup drawing process and the prediction of springback in the sidewall of drawn channel sections, even when a simple quadratic constitutive model is used.     

金属板条在圆柱形模中弯曲成形的大变形有限元分析

本文采用大变形弹塑性有限元法对金属板条在柱形模中的压弯成形过程进行了数值模拟,并与实验进行了比较。首先给出了纠正的拉格朗日有限元公式和基于弹塑性乘法分解的超弹性塑性本构关系。对接触摩擦问题的处理采用了罚函数法。通过对数值结果的分析得出了一些对弯曲工艺的设计有指导价值的结论。     

A new method for circular grid analysis in the sheet metal forming test

Computer vision systems are employed to determine the major and minor lengths of deformed elliptic grids while determining a sheet metal's workability. The existing method identifies the ellipse using the least squares analysis. It suffers two drawbacks: assumptions in direct conflict with the observed real-world processes and an undesirable property of orientation dependence. For the remedy, this paper presents a new method that, in addition to achieving the desired property of orientation invariance, discards assumptions that conflict with real-world processes. The proposed method is implemented and tested using simulated and real-world data. Results are reported and compared with those obtained by the existing method.     

Fracture prediction in stretch forming using finite element simulation combined with ductile fracture criterion

Summary  A criterion for ductile fracture is introduced in the finite element simulation of sheet metal forming. From the calculated histories of stress and strain in each element, the fracture initiation site and the critical stroke are predicted by means of the ductile fracture criterion. The calculations are carried out for axisymmetric stretch forming of various aluminium alloy sheets and their laminates clad by mild steel sheets. The predictions so obtained are compared with experimental observations. The results show that the combination of the finite element simulation and the ductile fracture criterion enables the prediction of forming limit in a wide range of sheet metals. Accepted for publication 11 August 1996     

Plotting isoclinics for hybrid photoelasticity and finite element analysis

Displacement-based finite element method formulations are coupled with stress-based photoelasticity analysis. As the stress field is discontinuous at the interelement boundaries, the introduced smoothing procedure enables the generation of high-quality digital images acceptable for hybird experimental-numerical techniques. The proposed methods are applicable for the analysis of static and dynamic results of experimental photoelasticity.