基于延性损伤和剪切损伤的铝合金成形极限预测

doi:10.13229/j.cnki.jdxbgxb201605026

摘要/Abstract

摘要： 针对应用拉伸失稳理论和缺陷理论获取铝合金成形极限图(FLD)的局限性,提出了一种基于延性损伤和剪切损伤的铝合金成形极限的获取方法。通过在损伤过程中引入裂纹状态变量,将FLD的获取转化为计算板材在不同应变路径下断裂时对应的极限主应变。本文以5083-O铝合金为例,设计了简单的缺陷试样加载试验和缺口试样纯剪切试验,利用有限元仿真的方式获取了材料在不同应变率下失效时对应的应力三轴度和剪应力比。通过圆顶冲头涨形的数值模拟,获取了板材在不同应变路径下断裂时对应的冲头行程、极限厚度和断裂成形极限图(FFLD),并与试验结果进行对比。结果表明:数值模拟获取的板材成形极限和试验结果基本吻合。将本文获取的FFLD应用于高速动车组司机室覆盖件的冲压成形效果分析中,预测的成形工件的失效形式和断裂位置与试验结果相吻合。

关键词: 金属材料, 成形极限图, 延性损伤, 剪切损伤, 缺陷预测

Abstract: To overcome the limitation of using tensile instability theory and essential hypothesis to guide the Forming Limit Diagram (FLD) of aluminum alloy, this paper proposes a forming limit prediction method based on ductile damage and shear damage theories. By introducing the macrocrack state variable, the FLD predicting process is transferred to compute the limit principal strain at fracture in various loading paths. The aluminum alloy 5083-O is chosen as the research object. Notched specimen loading test and gapped specimen pure shearing test are done with numerical simulation to obtain the stress triaxiality and shear stress ratio in different strain rates. Dome bulging process is carried out by numerical simulation to obtain the punch strokes, limit thickness and Fracture Forming Limit Diagram (FFLD). Simulation results and experimental results are basically consistent. FFLD is utilized to analyze the stamp forming effects of high-speed train cab covering panel. The predicted defect form and crack location show good agreement with experimental results.

Key words: metallic material, forming limit diagram, ductile damage, shear damage, forming defect prediction

中图分类号:

TG381

张学广, 刘纯国, 郑愿, 江仲海, 李湘吉. 基于延性损伤和剪切损伤的铝合金成形极限预测[J]. 吉林大学学报(工学版), 2016, 46(5): 1558-1566.

ZHANG Xue-guang, LIU Chun-guo, ZHENG Yuan, JIANG Zhong-hai, LI Xiang-ji. Forming limit prediction of aluminum alloy based on ductile damage and shear damage[J]. 吉林大学学报(工学版), 2016, 46(5): 1558-1566.

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