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     

厚钣金件压弯翻边与回弹的数值研究

在独立研制的板材冲压成形性分析软件KMAS中，组入可有效模拟厚钣金件压弯成形与回弹变形的三维退化曲壳单元模型，简述了考虑凹，凸模间隔可变的基于有限元网格双面接触算法以及回弹的处理技术，数值研究了铁路客车牵引架厚钣金件压弯翻边与回弹变形过程，并将压弯过程模拟结果与国外基于单面接触算法的商品化软件的模拟结果以有实验结果进行比较，最后，给出了该类问题回弹量的预示方法。     

基于六面体网格的向量式有限元分析及应用

基于向量式有限元基本原理,给出了八节点六面体等参实体单元的基本公式,通过投影方式将空间曲面六面体转换为投影六面体,采用参考面的逆向运动求解节点纯变形,通过单元形函的虚功方程计算节点内力;针对坐标模式和内力积分模式等关键问题提出了有效的处理方案。编制了六面体实体单元的数值计算程序,并进行工程结构算例分析。结果表明,所编制程序可有效模拟实体结构的静力、动力及大变形大位移行为分析,验证了本文理论和程序的正确性和实用性。     

基于六面体网格的向量式有限元分析及应用

基于向量式有限元基本原理,给出了八节点六面体等参实体单元的基本公式,通过投影方式将空间曲面六面体转换为投影六面体,采用参考面的逆向运动求解节点纯变形,通过单元形函的虚功方程计算节点内力;针对坐标模式和内力积分模式等关键问题提出了有效的处理方案。编制了六面体实体单元的数值计算程序,并进行工程结构算例分析。结果表明,所编制程序可有效模拟实体结构的静力、动力及大变形大位移行为分析,验证了本文理论和程序的正确性和实用性。     

降落伞膜索非线性有限元模拟

用膜单元和索单元模拟降落伞织物绳索系统,基于完全拉格朗日格式的非线性有限元方法编程计算降落伞的结构动力学特性。采用增量与迭代混合方法改善非线性计算的收敛特性并结合HHT隐式时间推进方法减小整体迭代计算量。使用修正应力应变张量导数的方法模拟膜单元单向应力状态并针对膜单元和索单元分别进行了非线性有限元计算验证。最后针对C-9型降落伞建立三维有限元模型,根据设定流速对伞衣施加均匀压强载荷,将模拟展开的结果与使用相同模型、不同方法商业软件的文献进行对比,显示了隐式非线性有限元方法模拟降落伞膜索系统大变形动力学的能力。     

304L/Q235B大面积金属板爆炸焊接物质点法模拟分析

大面积金属板材304L/Q235B的爆炸焊接过程涉及炸药爆轰、金属板材的高速碰撞和塑性变形等。采用有限元法计算模拟这个问题时,网格单元会发生扭曲畸变现象,导致计算精度下降,甚至出现单元负体积而使计算终止,并且炸药爆轰形成气体产物飞散过程也很难模拟。为了能模拟大面积金属板材的爆炸焊接整个过程并获得合理的技术工艺参数,采用物质点法进行三维数值模拟分析。物质点法作为一种无网格法,在模拟冲击动力学问题中主要采用显式积分算法。通过将拉格朗日质点单元与固定的欧拉背景网格相结合,可以实现爆炸焊接的复板与基板的高速碰撞、炸药滑移爆轰、金属板面的塑性变形过程的数值模拟,并给出爆炸复合板材的形变、有效塑性应变和复板与基板的碰撞速度的计算结果。采用物质点法模拟的复合板材变形与爆炸焊接实验结果基本一致。计算复板与基板的碰撞速度这个重要的物理参数时,物质点法与Richter理论公式的相对误差不超过13%。数值计算和实验结果表明,物质点法在数值精度和计算效率方面具有优势,物质点法是研究金属焊接爆炸问题的一种有效数值方法。     

大直径超长灌注桩弹塑性有限元分析

本文在对包含点面接触单元的弹塑性有限元模型进行分析和验证的基础上,以苏通大桥的大型灌注桩为例进行了数值模拟计算。结果显示,该包含点面接触单元的弹塑性有限元法是可靠的,能模拟桩土之间的大变形,其数值模拟结果可为工程的桩基设计提供依据。     

基于静力响应面的结构有限元模型修正方法

提出了基于静力响应面的结构有限元模型修正方法.运用响应面方法,将结构静力响应和结构参数之间复杂的隐式关系用显式函数近似表达出来;在此响应面模型(函数)基础上,通过优化计算对结构有限元模型参数进行修正.阐述了基于静力响应面的结构有限元模型修正方法的基本理论和一般实现过程.对两跨连续梁结构的静力模型修正数值算例分析结果表明:基于静力响应面的有限元模型修正方法可以减少结构有限元计算的次数、提高模型修正的优化效率,结构有限元模型修正结果具有可接受的精度.     

RTM充模过程数值模拟的隐式有限元算法

建立了基于欧拉方法描述树脂传递模塑(RTM)工艺充模过程的基本数学方程,并采用有限元隐式时间积分方法对基本方程进行了数值求解．编制了基于隐式有限元算法及传统有限元控制体算法的程序,通过具体算例比较了这两种算法的优缺点．与传统的有限元控制体法相比,该文提出的隐式有限元算法能节省计算时间,特别适合于单元、节点数目多的情况．隐式有限元算法是一种纯有限元方法,不需要使用控制体积技术,采用该算法计算出的流动前沿与时间步长无关。     

考虑等效曲率的超二次曲面单元非线性接触模型

基于连续函数包络的超二次曲面单元可有效地描述自然界和工业生产中的非球体颗粒形态, 并通过非线性迭代方法精确计算单元间的接触力. 对于具有复杂几何形态的超二次曲面单元, 线性接触模型不能准确地计算不同接触模式下的作用力. 考虑超二次曲面单元相互作用时不同颗粒形状及表面曲率的影响, 本文发展了相应的非线性黏弹性接触模型. 该模型将不同接触模式下的法向刚度和黏滞力统一表述为单元间局部接触点处等效曲率半径的函数; 切向接触作用则借鉴基于Mohr-Coulomb摩擦定律的球体单元非线性接触模型的计算方法. 为检验超二次曲面单元接触模型的可靠性, 对球形颗粒间的法向碰撞、椭球体颗粒间的斜冲击过程、圆柱体的静态堆积和椭球体的动态卸料过程进行离散元模拟, 并与有限元数值结果及试验结果进行对比验证. 计算表明, 考虑接触点处等效曲率半径的超二次曲面非线性接触模型可准确地计算单元间的接触碰撞作用, 并合理地反映非球形颗粒体系的运动规律. 在此基础上进一步分析了不同长宽比和表面尖锐度对卸料过程中颗粒流动特性的影响, 为非球形颗粒材料的流动特性分析提供了一种有效的离散元方法.      

SECTIONAL FINITE ELEMENT ANALYSIS OF COUPLED DEFORMATION BETWEEN ELASTOPLASTIC SHEET METAL AND VISCO-ELASTOPLASTIC BODY

The present paper is devoted to developing a new numerical simulation method for the analysis of viscous pressure forming (VPF), which is a sheet flexible-die forming (FDF) process. The pressure-carrying medium used in VPF is one kind of semisolid, flowable and viscous material and its deformation behavior can be described by the visco-elastoplastic constitutive model. A sectional finite element model for the coupled deformation analysis between the visco- elastoplastic pressure-carrying medium and the elastoplastic sheet metal is proposed. The resolution of the Updated Lagrangian (UL) formulation is based on a static explicit approach. The frictional contact between sheet metal and visco-elastoplastic pressure-carrying medium is treated by the penalty function method. Coupled deformation between sheet metal and visco-elastoplastic pressure-carrying medium with large slip is analyzed to validate the developed algorithm. Finally, the viscous pressure bulging (VPB) process of DC06 sheet metal is simulated. Good agreement between numerical simulation results and experimental measurements shows the validity of the developed algorithm.     

高强度钢板热成形数值模拟-静力显式

在已建立的高强度钢热成形热、力、相变耦合本构方程的基础上,基于虚功率方程及持续平衡方程建立了热成形静力显式多场耦合有限元列武。将热成形过程中的相变潜热引入温度场,并进行了有限元分析;在自主开发的商业化金属成形CAE软件KMAS(King-Mesh Analysis System)基础上,开发了考虑多场耦合的非线性、大变...     

Strain localization analysis using a large deformation anisotropic elastic–plastic model coupled with damage

Sheet metal forming processes generally involve large deformations together with complex loading sequences. In order to improve numerical simulation predictions of sheet part forming, physically-based constitutive models are often required. The main objective of this paper is to analyze the strain localization phenomenon during the plastic deformation of sheet metals in the context of such advanced constitutive models. Most often, an accurate prediction of localization requires damage to be considered in the finite element simulation. For this purpose, an advanced, anisotropic elastic–plastic model, formulated within the large strain framework and taking strain-path changes into account, has been coupled with an isotropic damage model. This coupling is carried out within the framework of continuum damage mechanics. In order to detect the strain localization during sheet metal forming, Rice’s localization criterion has been considered, thus predicting the limit strains at the occurrence of shear bands as well as their orientation. The coupled elastic–plastic-damage model has been implemented in Abaqus/implicit. The application of the model to the prediction of Forming Limit Diagrams (FLDs) provided results that are consistent with the literature and emphasized the impact of the hardening model on the strain-path dependency of the FLD. The fully three-dimensional formulation adopted in the numerical development allowed for some new results – e.g. the out-of-plane orientation of the normal to the localization band, as well as more realistic values for its in-plane orientation.     

大变形中摩擦接触问题的数值模拟及应用

大变形的摩擦接触是复杂的非线性问题 ,本文介绍了一种处理摩擦接触问题的数值方法。采用接触单元技术模拟接触界面 ,基于弹塑性理论形式的非经典Coulomb摩擦定律及罚函数方法建立了摩擦接触的增量本构关系。结合大变形的增量分析格式给出了积分摩擦接触本构方程的回映方法。这种处理摩擦接触问题的方法计算简单、使用方便。给出的计算实例及应用实例说明了方法的精度与稳定性     

板材冲压成形有限元数值模拟界面摩擦约束处理方法

基于弹塑性大变形板材冲压成形增量有限元法,采用线性弹簧单元提出一种空间三维板材冲压成形等效界面摩擦力的处理方法.这种方法的优点是可以反映界面摩擦力的同步、被动产生效果,同时它还可以保证约束后刚度矩阵的对称性.将提出的摩擦约束处理算法引入自主开发的板材成形模拟软件FASTAMP,计算了汽车油底壳的成形过程,计算结果的厚度分布与实际冲压件吻合比较好,验证了等效界面摩擦力约束处理方法的有效性.     

Application of the continuum shell finite element SHB8PS to sheet forming simulation using an extended large strain anisotropic elastic–plastic formulation

This paper proposes an extension of the SHB8PS solid–shell finite element to large strain anisotropic elasto-plasticity, with application to several non-linear benchmark tests including sheet metal forming simulations. This hexahedral linear element has an arbitrary number of integration points distributed along a single line, defining the “thickness” direction; and to control the hourglass modes inherent to this reduced integration, a physical stabilization technique is used. In addition, the assumed strain method is adopted for the elimination of locking. The implementation of the element in Abaqus/Standard via the UEL user subroutine has been assessed through a variety of benchmark problems involving geometric non-linearities, anisotropic plasticity, large deformation and contact. Initially designed for the efficient simulation of elastic–plastic thin structures, the SHB8PS exhibits interesting potentialities for sheet metal forming applications—both in terms of efficiency and accuracy. The element shows good performance on the selected tests, including springback and earing predictions for Numisheet benchmark problems.     

Rate-dependent quasi-flow corner theory for elastic/visco-plastic materials

A rate-dependent quasi-flow plastic constitutive model with punch-speed sensitivity is proposed for the large-deformation sheet metal forming process, which is based on the quasi-flow corner theory and U–L formulation for the virtual work-rate equation. Three kinds of constitutive theories with strain rate dependence, classical flow theory, deformation theory with rate form obeying non-orthogonality rule, and the present quasi-flow corner theory, are introduced into the U–L finite element formulation to simulate the deformation localization processes of plane strain tension in order to investigate effects of strain rate sensitivity on the localizing deformation characters. Furthermore, three kinds of typical forming processes sheet metals, one being an uniaxial stretching and another being a square cup drawing with circular blank, and third being a deep drawing of an oil pan, actual industrial forming part, are also numerically simulated by the present model and compared with experimental results. Good agreement between numerical simulation and experimental ones exhibits the validity of the quasi-flow corner theory.     

Numerical study of the plastic behaviour in tension of welds in high strength steels

The influence of the mismatch between material properties and constraint on the plastic deformation behaviour of the heat affected zone of welds in high strength steels is investigated in this study, using finite element simulations. An elastoplastic implicit three-dimensional finite element code (EPIM3D) was used in the analysis. The paper presents the mechanical model of the code and the methodology used for the numerical simulation of the tensile test of welded joints. Numerical results of the tensile test of welded samples with different hypothetical widths for the Heat Affected Zone and various material mismatch levels are shown. The analysis concerns the overall strength and ductility of the joint and in relation to the plastic behaviour of the heat affected zone. The influence of the yield stress, tensile strength and constraint on the stress and plastic strain distribution in the soft heat affected zone is also discussed.     

考虑动静摩擦影响的可接触型裂纹动态响应的隐式算法

提出一种考虑裂纹面摩擦影响的可接触型裂纹动力反应的时域隐式计算方法。这一方法不但可以较好地描述裂纹面间的碰撞过程及反映动接触时裂纹面间动、静摩擦力的影响，而且使动接触问题分析中的系统矩阵成为对称型式，在弹塑性有限元迭代过程中，无需增加额外的迭代即可求得较好的结果。数值结果表明本文方法具有良好的稳定性和较高的精度。     

Springback analysis for sheet forming processes by explicit finite element method in conjunction with the orthogonal regression analysis

A new method to evaluate the amount of springback in sheet forming processes based on the explicit finite element method and the orthogonal regression analysis is presented in this paper. To calculate springback accurately, a simple but effective contact searching algorithm is described and Lagrangian multiplier method was used to evaluate the contact force. The loading and unloading process could be simulated within one code. The numerical results by the present method were compared with the results by the commercial dynamic explicit code LS-DYNA3D, also with the experimental results and very good agreement was drawn. In order to obtain the springback conveniently for the purpose of practical use, the orthogonal regression analysis was implemented to establish the explicit relationship between the springback and some design parameters. The present method has been applied to the analysis of some actual sheet forming processes and very good agreement between the numerical results and the experimental results in the final geometry was obtained.