吉林大学学报(工学版) ›› 2019, Vol. 49 ›› Issue (4): 1272-1279.doi: 10.13229/j.cnki.jdxbgxb20180146

• • 上一篇    

基于增量控制的型材拉弯轨迹设计及有限元仿真

张学广1,2(),贾明萌3,刘纯国2,何广忠1   

  1. 1. 中车长春轨道客车股份有限公司 工程规划发展部,长春 130051
    2. 吉林大学 辊锻工艺研究所,长春 130022
    3. 吉林交通职业技术学院 汽车工程学院,长春 130012
  • 收稿日期:2018-02-04 出版日期:2019-07-01 发布日期:2019-07-16
  • 作者简介:张学广(1989?),男,高级工程师,博士. 研究方向:车体制造工艺. E?mail:zxg13@mails.jlu.edu.cn
  • 基金资助:
    国家自然科学基金项目(51575231)

Trajectory design and FE simulation for profile stretch bending based on incremental control method

Xue⁃guang ZHANG1,2(),Ming⁃meng JIA3,Chun⁃guo LIU2,Guang⁃zhong HE1   

  1. 1. Engineering Planning and Development Department, CRRC Changchun Railway Vehicles Co. , Ltd. , Changchun 130051, China
    2. Rolling Forming Research Institute, Jilin University, Changchun 130022, China
    3. College of Automotive Engineering, Jilin Communication Polytechnic, Changchun 130012, China
  • Received:2018-02-04 Online:2019-07-01 Published:2019-07-16

摘要:

根据型材拉弯设备结构和成形工况,将夹钳加载量等效为拉伸缸沿转臂的拉伸量和转臂的转角,并提出了一种基于增量控制的型材拉弯轨迹设计方法。通过沿轴线方向将型材目标形状划分成多个成形段,并求解出每个成形段对应的拉伸增量和转角增量,实现型材拉弯成形中加载量的独立分配与控制。以轨道车辆车顶乙形不锈钢弯梁作为研究对象,建立了一种基于连接器单元的型材拉弯有限元模型,并将计算得到的加载增量应用于工件成形效果仿真中,实现了拉弯轨迹的参数化调控。根据仿真结果中工件的形状误差与表面翘曲量分析了拉弯缺陷的成因,并对拉弯轨迹进行了针对性的修正,提升了工件成形效果。采用修正后的拉弯轨迹进行工件成形试验,仿真结果与试验结果相吻合。

关键词: 材料合成与加工工艺, 型材拉弯, 轨迹设计, 增量控制, 数值模拟

Abstract:

According to the structure of the stretch bending equipment and the loading condition, the loading capacity of the jaw is equated to the tensile strength of the drawing cylinder and rotation angle of the turning arm, and a trajectory design method for profile stretch bending based on incremental control is proposed. By dividing the target shape into several forming sections and calculating the tensile strength increment and rotation angle increment, the independent distribution and control of the loading capacity are realized. The Z-shaped stainless steel curved roof beam is selected as the research object. The profile stretch bending FE simulation model composed of connector units is established. The calculated loading increment is applied in predicting the forming effects of the workpiece, which realizes the parameterized regulation of the loading trajectory. The forming defect analysis and pertinent modification are conducted according to the shape error and the surface warpage in the simulation results, which improve the forming effects. The modified trajectory is adopted in the forming test, and the simulation results meet well with the experimental results.

Key words: material synthesis and processing technology, profile stretch bending, trajectory design, incremental control, numerical simulation

中图分类号: 

  • TG386

图1

张臂式拉弯机构图"

图2

成形段内加载增量示意图"

图3

工件目标形状与截面尺寸"

图4

基于连接器单元的拉弯有限元模型"

图5

拉伸缸及转臂的加载量"

图6

工件成形效果"

图7

拉伸缸及转臂的加载量对比"

图8

型材末端运行轨迹对比"

表1

工件成形效果对比"

轨迹 最大主应变 回弹后曲率/mm

表面翘曲

/mm

形状误差

/mm

大弧 小弧 大弧 小弧
原拉弯 0.033 0.273 7068.2 351.4 3.44 4.16
修正后 0.107 0.214 7024.0 350.9 1.09 1.34

图9

拉弯成形试验"

图10

试验件"

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