吉林大学学报(工学版) ›› 2025, Vol. 55 ›› Issue (11): 3564-3574.doi: 10.13229/j.cnki.jdxbgxb.20240257

• 材料科学与工程 • 上一篇    

基于磁流变弹性体商用车防护梁绕弯成形

李义1(),黄伟鹏1,程敏2(),梁继才1   

  1. 1.吉林大学 材料科学与工程学院,长春 130022
    2.吉林大学 机械与航空航天学院,长春 130022
  • 收稿日期:2024-03-13 出版日期:2025-11-01 发布日期:2026-02-03
  • 通讯作者: 程敏 E-mail:henrylee@jlu.edu.cn;792493209@qq.com
  • 作者简介:李义(1974-),男,教授,博士. 研究方向:材料先进成型技术.E-mail:henrylee@jlu.edu.cn
  • 基金资助:
    吉林省科技发展计划项目(20220201048);吉林省科技发展计划项目(20210201109GX)

Roll bending forming of commercial vehicle bumper beams based on magnetorheological elastomers

Yi LI1(),Wei-peng HUANG1,Min CHENG2(),Ji-cai LIANG1   

  1. 1.College of Materials Science and Engineering,Jilin University,Changchun 130022,China
    2.School of Mechanical and Aerospace Engineering,Jilin University,Changchun 130022,China
  • Received:2024-03-13 Online:2025-11-01 Published:2026-02-03
  • Contact: Min CHENG E-mail:henrylee@jlu.edu.cn;792493209@qq.com

摘要:

本文采用绕弯成形工艺将“日”字形截面型材弯曲成商用车防护梁。在实际加工成形过程中,型材常出现起皱、截面畸变等成形缺陷。为此,利用ABAQUS有限元软件对无芯模支撑型材成形过程进行深入的数值模拟,旨在分析缺陷形成机理。基于此分析,本文设计并研究了一种新型芯模——新型磁控芯模,该芯模不仅对“日”字形结构型材的弯曲成形表现出优异的成形质量,还能显著提升传统芯模成形工艺的性能。此外,通过改变弯曲半径、模具间隙等成形参数,本文探究了型材弯曲的极限工艺参数,在保证精度的前提下寻求极限工艺参数。

关键词: 商用车防护梁, 磁流变弹性体, 力学测试, 新型磁控芯模

Abstract:

This paper adopts the roll bending forming process to bend profiles with a "日" shaped cross-section into commercial vehicle bumper beams. During the actual processing and forming process, profiles often exhibit forming defects such as wrinkling and cross-sectional distortion. To address this, an in-depth numerical simulation of the coreless mandrel-supported profile forming process was conducted using ABAQUS finite element software, aimed at analyzing the mechanism of defect formation. Based on this analysis, a new type of mandrel—a novel magnetically controlled mandrel—was designed and studied. This mandrel not only exhibits excellent forming quality in bending "日" shaped structural profiles, but also significantly improves the performance of the traditional mandrel forming processes. Moreover, by altering forming parameters such as the bending radius and die gap, the paper explored the limits of process parameters for profile bending, seeking to find the extreme process parameters while ensuring accuracy.

Key words: commercial vehicle bumper beam, magnetorheological elastomer, mechanical testing, novel magnetically controlled mandrel

中图分类号: 

  • TG386

表1

高强度钢B700L的力学性能"

杨氏模量/GPa密度/(kg·m-3泊松比
2167 8500.22

图1

型材有限元模型示意图"

表2

MREs复合材料的配方 (phr)"

样 品MRE-60CIP
总共381.5
NR70
BR30
羰基铁粉230
硅炭黑30
少层石墨烯3
氧化锌5
硬脂酸1
防氧化剂40202
防氧化剂RD2
促进剂CZ2
增塑剂古马龙7.5
硫磺2

图2

自主研发的磁场发生装置"

图3

绕弯成形示意图"

图4

型材绕弯前后的截面变形图"

图5

无芯情况模下的RDB工艺有限元模拟"

图6

MRE-0CIP和MRE-60CIP扫描电镜图"

图7

MRE-60CIP力学性能"

表3

不同CIPs含量的MREs力学性能"

样品

MRE-

0 CIP

MRE-

30 CIP

MRE-

60 CIP

拉伸强度16.1817.7819.46
100%应变下的应力0.781.562.32
300%应变下的应力1.484.496.23
压缩模量4.044.976.59

表4

不同CIPs含量的MREs磁流变效应"

样品G0/MPaGmax/MPa(Gmax-G0)/G0/%
MRE-0CIP0.9750.9790.410
MRE-30CIP1.7111.96815.001
MRE-60CIP1.8162.22522.501

图8

磁控芯模下的RDB工艺有限元模拟"

图9

不同弯曲半径下的Mises应力云图和壁厚云图"

图10

不同弯曲半径"

图11

不同间隙参数下的Mises应力分布云图"

图12

不同间隙参数下的横向位移分布云图"

图13

模具间隙变化对增厚率的影响曲线"

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