多凸模主动控制弯曲管材挤压成形机理研究
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摘要
管材弯曲成形作为管材塑性加工的一种工艺方法，在工业生产中占有重要地位。用管材制造的弯曲零件，不论是平面弯曲件，还是空间弯曲件，其应用广泛。管材弯曲成形过程中，由于工艺及设备等因素的限制，不可避免的存在各种缺陷，如内侧壁增厚、起皱，外侧壁减薄、破裂等。为在实际的生产中避免这些缺陷，需要研究一种新的生产工艺来满足实际的生产。多凸模主动控制制备管材弯曲件，借鉴多点成形技术的形式，通过控制多个凸模的挤压加载模式和凸模形式，获得一次成形的平面或者空间的弯曲管件的新的工艺方法。
本文设计了双凸模，三凸模，四凸模多个挤压模型分别进行模拟，通过对多个模型模拟的后处理分析，研究了双凸模，三凸模，四凸模挤压成形弯曲管件的规律，探讨多凸模主动控制制备管材弯曲件的机理。
双凸模挤压成形弯曲管件采用有限元法，主要分析了双凸模加载方式对材料流动速度场的影响。双凸模恒速加载能制备平面内单向的弯曲管件，变速加载能得到平面内双向弯曲的管件。双凸模之间的加载速度差是影响速度场不平衡的主要因素，速度差值的大小，影响着管件的弯曲曲率。对应管件的弯曲曲率，有一个最佳的速度差值与最大的曲率相对应。双凸模速度差是一个多因素耦合作用结果，它受到模型结构，管件壁厚，坯料高度等条件的影响。在一定的条件下，双凸模速度差有相应的约束条件。
三凸模挤压成形弯曲管件，主要分析了三凸模成形弯曲管件的规律，对各凸模的形状，速度差与成形弯曲管件曲率的关系给出了解释。三凸模速度差与弯管的曲率关系，与双凸模相同；第三凸模的形状影响这弯管转向角的大小。
四凸模挤压成形弯曲管件，通过双凸模和三凸模挤压给予的启示，设定四凸模挤压的加载模式，得到了一个空间弯曲非常明显的管件。四凸模挤压的材料流动的速度场更加复杂，引入空间速度场，分析弯曲管件的空间转向和弯曲趋势，限定成形空间弯曲管件的条件，并对成形后的弯管质量等进行了研究。空间速度场是造成弯管空间弯曲的主要因素；四凸模变速加载能够得到一个空间弯曲明显，质量良好的弯曲管件。
不同形状的弯曲管件，可通过改变多凸模的加载方式和模具结构得到。双凸模得到平面弯管，多凸模挤压不仅能够制备平面弯管，而且能得到空间弯管。
As a technological method of pipe plastic processing, pipe bending plays an role inindustrial production. Bending parts made with pipe, including plane bending and spacebending, has a wide range of applicant. In the process of pipe bending forming, because ofconstraint factors including process and equipment and so on, the existence of various defectssuch as medial wall thickening, wrinkling, thinning of the outer wall, rupture is inevitable. Inorder to avoid these defects in practical applicant, we study a new production process to meetthe actual production. The extrusion with many punch actively controlled to make pipebending parts, drawing the concept of multi-point forming technology, is a new technologymethod which can get a plane or space forming tube by controlling the extrusion loadingmode and the punch shape.
In order to study the mechanism on the extrusion with many punch actively controlled tomake pipe bending parts, this article designs different models including double punch, threepunch, punch four, six punch model to simulate respectively. Through the analysis of thesimulation results, we find the universal laws about the extrusion with many punch activelycontrolled to make pipe bending parts.
We make use of finite element method to mainly study the velocity field of the doublepunch simulation model. Plane bending tube can be prepared by constant loading, and spacebending tube can be got by variational loading mode. The velocity differential between thedouble punch is the main factor that affects the balance of the velocity filed. The size ofvelocity differential makes effect to the pipe curvature. The relationship of between thevelocity differential and the pipe curvature is that there exists the best velocity differential tothe largest curvature of the pipe. The velocity differential between the double punch is a resultof coupling of multiple factors, which is influenced by the structure of the model, the wallthickness of the pipe, the height of blanks and so on. In certain conditions, exist thecorresponding constraints to the double-punch speed difference.
The extrusion with three punch to prepare bending tubes mainly analyzes the rules of theformed bending tube, and give explanation to the bending tube shape and the relationshipbetween the speed differential and the curvature of the bending tube. The law speeddifferential and the curvature is the same to the extrusion with two punch, and the more thescale of the third punch, the bigger the turning angle of the bending tube.
The extrusion with four punch to prepare bending tubes, through the inspiration theextrusion of two punch and three punch, set the loading mode, and a very clear space curvedpipe is prepared. The material flowing velocity filed is more complex. We make use of spacevelocity filed to analyze the turning and bending trend of the bending tube, and make a limitto the bending forming, moreover research the quality of the formed tube. Space velocity isthe main factor that causes the tube to bend; this method can prepare a space bending tube which have o good surface.
The tubes of different shapes can be prepared by changing the loading mode and thestructure of the die. The extrusion with two punch get a plane bending tube, and The extrusionwith more punch can prepare a space or plane bending tube.
本文设计了双凸模，三凸模，四凸模多个挤压模型分别进行模拟，通过对多个模型模拟的后处理分析，研究了双凸模，三凸模，四凸模挤压成形弯曲管件的规律，探讨多凸模主动控制制备管材弯曲件的机理。
双凸模挤压成形弯曲管件采用有限元法，主要分析了双凸模加载方式对材料流动速度场的影响。双凸模恒速加载能制备平面内单向的弯曲管件，变速加载能得到平面内双向弯曲的管件。双凸模之间的加载速度差是影响速度场不平衡的主要因素，速度差值的大小，影响着管件的弯曲曲率。对应管件的弯曲曲率，有一个最佳的速度差值与最大的曲率相对应。双凸模速度差是一个多因素耦合作用结果，它受到模型结构，管件壁厚，坯料高度等条件的影响。在一定的条件下，双凸模速度差有相应的约束条件。
三凸模挤压成形弯曲管件，主要分析了三凸模成形弯曲管件的规律，对各凸模的形状，速度差与成形弯曲管件曲率的关系给出了解释。三凸模速度差与弯管的曲率关系，与双凸模相同；第三凸模的形状影响这弯管转向角的大小。
四凸模挤压成形弯曲管件，通过双凸模和三凸模挤压给予的启示，设定四凸模挤压的加载模式，得到了一个空间弯曲非常明显的管件。四凸模挤压的材料流动的速度场更加复杂，引入空间速度场，分析弯曲管件的空间转向和弯曲趋势，限定成形空间弯曲管件的条件，并对成形后的弯管质量等进行了研究。空间速度场是造成弯管空间弯曲的主要因素；四凸模变速加载能够得到一个空间弯曲明显，质量良好的弯曲管件。
不同形状的弯曲管件，可通过改变多凸模的加载方式和模具结构得到。双凸模得到平面弯管，多凸模挤压不仅能够制备平面弯管，而且能得到空间弯管。
As a technological method of pipe plastic processing, pipe bending plays an role inindustrial production. Bending parts made with pipe, including plane bending and spacebending, has a wide range of applicant. In the process of pipe bending forming, because ofconstraint factors including process and equipment and so on, the existence of various defectssuch as medial wall thickening, wrinkling, thinning of the outer wall, rupture is inevitable. Inorder to avoid these defects in practical applicant, we study a new production process to meetthe actual production. The extrusion with many punch actively controlled to make pipebending parts, drawing the concept of multi-point forming technology, is a new technologymethod which can get a plane or space forming tube by controlling the extrusion loadingmode and the punch shape.
In order to study the mechanism on the extrusion with many punch actively controlled tomake pipe bending parts, this article designs different models including double punch, threepunch, punch four, six punch model to simulate respectively. Through the analysis of thesimulation results, we find the universal laws about the extrusion with many punch activelycontrolled to make pipe bending parts.
We make use of finite element method to mainly study the velocity field of the doublepunch simulation model. Plane bending tube can be prepared by constant loading, and spacebending tube can be got by variational loading mode. The velocity differential between thedouble punch is the main factor that affects the balance of the velocity filed. The size ofvelocity differential makes effect to the pipe curvature. The relationship of between thevelocity differential and the pipe curvature is that there exists the best velocity differential tothe largest curvature of the pipe. The velocity differential between the double punch is a resultof coupling of multiple factors, which is influenced by the structure of the model, the wallthickness of the pipe, the height of blanks and so on. In certain conditions, exist thecorresponding constraints to the double-punch speed difference.
The extrusion with three punch to prepare bending tubes mainly analyzes the rules of theformed bending tube, and give explanation to the bending tube shape and the relationshipbetween the speed differential and the curvature of the bending tube. The law speeddifferential and the curvature is the same to the extrusion with two punch, and the more thescale of the third punch, the bigger the turning angle of the bending tube.
The extrusion with four punch to prepare bending tubes, through the inspiration theextrusion of two punch and three punch, set the loading mode, and a very clear space curvedpipe is prepared. The material flowing velocity filed is more complex. We make use of spacevelocity filed to analyze the turning and bending trend of the bending tube, and make a limitto the bending forming, moreover research the quality of the formed tube. Space velocity isthe main factor that causes the tube to bend; this method can prepare a space bending tube which have o good surface.
The tubes of different shapes can be prepared by changing the loading mode and thestructure of the die. The extrusion with two punch get a plane bending tube, and The extrusionwith more punch can prepare a space or plane bending tube.
引文
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[3]王同海.管材塑性加工技术[M].北京:机械工业出版社.1998.8
[4]王广春.金属体积成形工艺计数值模拟技术[M].北京:机械工业出版社.2009.11
[5]航空制造工程手册总编委会.航空制造工程手册:飞机钣金工艺[M] .北京:航空工业出版社, 1992.
[6] Lin Y, Yang H, Thin-walled tube precision bending process and FEM simulation. In:Proceedings of the 4th International Conference on Frontiers of Design and Manufacturing[C].Beijing: International Academic Publishers, 2000: 305-308.
[7]王志强,刘晓飞.管和板的热应力弯曲工艺[J ] .塑性工程学报，2000,7(2):55~57
[8]胡忠.大直径厚壁管中频感应局部加热弯管工艺研究[J].中国机械工程,1998,9(3):19-22.
[9] Murata M, Yamnamnoto S, Suzuki H. Development of new flexible bending CNCmachine for circular tube[J]. Advanced Technology of Plasticity,1993(1):435~440
[10] Klaus B. Muller. Bending of extruded profiles during extrusion process. InternationalJournal of Machine Tools & Manufacture 46 (2006) :1238–1242.
[11] Frank Vollertsen ,Axel Sprenger ,Jurgen Krraus ,et al. Extrusion, channel, and profilebending: a review. Journal of Materials Processing Technology,1997 ,87 :1-27.
[12]赵臻淞,杨合,林艳,詹梅.管材弯曲工艺研究新进展[J].金属成形工艺,2002,(2):1-5
[13]申世军,杨合,詹梅等.铝合金大口径薄壁管数控弯曲试验研究[J].塑性工程学报,2007,14(6):78-82
[14] Chen, F.-K., et al., Finite element analysis of multi-hole extrusion of aluminum-alloytubes, J. Mater. Process. Tech. (2008), doi:10.1016/j.jmatprotec.2007.11.292
[15] Kuriyama S , Aida T. Theoretical analysis of bending of tube having ununiformdistribution of temperature by high frequency induction heating [A] . Proceeding of theFourth International Conference on Technology of Plasticity [ C], Beijing,1993 :464～469
[16] Tang N C. Plastici2deformation analysis in tube bending[J ] .International Journal ofPressure Vessels and Piping , 2000 ,77 :751～759
[17] Junichi Endow, Tadao Murota. On the Flanening of Cros-sion-Section of Circular Tubesin Uniform Bending[J].Advanced Technology of Poasticity,1984(1):285-290
[18] Kyriakides S, Corona E, Miller JE. E5ect of yield surface evolution on bending inducedcross sectional deformation of thin-walled sections. International Journal of Plasticity2004;20:607–18.
[19] Forde Paulsen, Torgeir Welo. Application of numerical simulation in the bending ofaluminium-alloy profiles[J]. Journal of Materials Processing Technology, l996, 58:274-285
[20]吉田正敏,藤原昭文.アルミ中空矩形断面形材の曲げ加工におけるしわ,ひずみ量予测[J ] .塑性と加工, 1997 ,38 (440) :803～808
[21] Pan K, Stelson KA. On the plastic deformation of a tube during bending[J ] .Journal ofEngineering for Industry Transactions of the ASME, 1995 ,117 :494～499
[22] Hu Z , Li J Q. Computer simulation of pipe2bending processes with small bending radiususing local induction heating [ J ] .Journal of Materials Processing Technology , 1999 ,91 :75～79
[23] Miller J E , et al . On bend2strtched of aluminiun extruded tubes2I :experiments[J ] .International Journal of Mechanical Science , 2001 ,43 :1283～1317
[24]张旭光.数控弯管回弹的解析—数值模拟研究[D] .西北工业大学,2003
[25]周飞,苏丹,彭颖红,等.有限体积法模拟铝型材挤压成形过程[J].中国有色金属学报,2003, 13 (11).
[26]王勖成，邵敏.有限单元法基本原理和数值方法[M]，北京：清华大学出版社，1995.
[27]李传民，王向丽，闫华军等.DEFORM5.03金属成形有限元分析实例指导教程[ M]，北京：机械工业出版社，2007.
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