超声振动-单点增量复合成形过程中成形力的分析与建模
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摘要
成形力过大一直是制约单点增量成形技术发展的主要问题之一,针对该问题将超声振动引入单点增量成形技术中,用以降低成形力。为定量揭示超声振动降低成形力的作用机制,对超声振动-单点增量复合成形技术的工作原理和运动规则进行分析总结,取成形接触区域板料微元作为重点分析对象,建立球坐标应力平衡方程,并对接触面上的各向应力进行积分,提炼板料变形处的受力情况并对其进行解析化表达,构建一种关于超声振动-单点增量复合成形技术成形力的解析模型,借此得到施振参数和工艺参数对成形力的影响规律。通过试验对解析模型进行验证,设计开发超声振动主轴及板料夹持系统,搭建Kistler的成形力测试系统。试验表明超声振动可以有效降低成形力,同时存在合适范围的频率和振幅使得成形力达到极小值,且试验中的施振参数和工艺参数对成形力的影响规律与理论计算结果具有很好的一致性,验证了解析模型的正确有效性。研究成果为深入分析超声振动对单点增量成形力的影响提供了理论及技术依据。
The excessive forming force has been one of the main problems in the development of single point incremental formingtechnology(SPIF). Therefore, ultrasonic vibration is introduced into SPIF to reduce the force. The working principle and moving ruleof ultrasonic vibration single point incremental forming technology(UV-SPIF) are analyzed to quantitatively reveal the mechanism ofreducing the force of UV-SPIF. The spherical coordinate stress equilibrium equation is established by taking the sheet microelementas the analysis object. The each stress is integrated on the forming interface. The stress condition of the deformation area is revealedand the expression is analyzed. An analytical model for the force of UV-SPIF is constructed to obtain the influence rule of thevibration parameters and process parameters on the force. In addition, the analytical model is verified by experiments. The ultrasonicvibration spindle and the clamping system are developed. Force test system of Kistler is built. Experiments show that the ultrasonicvibration can effectively reduce the force. At the same time, the frequency and amplitude of the appropriate range will make the forcereach a minimum. In addition, the influence laws of the vibration parameters and process parameters on the force are consistent withthe theoretical calculation results, and the validity of the analytical model is verified. A theoretical and technical basis is provided forin-depth analysis of the influences of ultrasonic vibration on single point incremental forming force.
The excessive forming force has been one of the main problems in the development of single point incremental formingtechnology(SPIF). Therefore, ultrasonic vibration is introduced into SPIF to reduce the force. The working principle and moving ruleof ultrasonic vibration single point incremental forming technology(UV-SPIF) are analyzed to quantitatively reveal the mechanism ofreducing the force of UV-SPIF. The spherical coordinate stress equilibrium equation is established by taking the sheet microelementas the analysis object. The each stress is integrated on the forming interface. The stress condition of the deformation area is revealedand the expression is analyzed. An analytical model for the force of UV-SPIF is constructed to obtain the influence rule of thevibration parameters and process parameters on the force. In addition, the analytical model is verified by experiments. The ultrasonicvibration spindle and the clamping system are developed. Force test system of Kistler is built. Experiments show that the ultrasonicvibration can effectively reduce the force. At the same time, the frequency and amplitude of the appropriate range will make the forcereach a minimum. In addition, the influence laws of the vibration parameters and process parameters on the force are consistent withthe theoretical calculation results, and the validity of the analytical model is verified. A theoretical and technical basis is provided forin-depth analysis of the influences of ultrasonic vibration on single point incremental forming force.
引文
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[20]柏朗,李言,杨明顺,等.超声振动单点增量成形力研究[J].机械科学与技术,2018,37(2):270-275.BAI Lang,LI Yan,YANG Mingshun,et al.Research on forming force in single point incremental forming with ultrasonic vibration[J].Mechanical Science and Technology for Aerospace Engineering,2018,37(2):270-275.
[21]高永国,王德辉.1060铝合金动态力学性能的试验研究[J].工具技术,2015,49(10):48-51.GAO Yongguo,WANG Dehui.Investigation on dynamic mechanical properties of 1060 pure Aluminium[J].Tool Engineering,2015,49(10):48-51.
[22]李鹏阳,徐海峰,安武润,等.板料单点渐进成形力仿真与试验研究[J].应用力学学报,2015,32(6):1062-1068.LI Pengyang,XU Haifeng,AN Wurun,et al.Simulation and experimental study on single point incremental forming force of sheet[J].Chinese Journal of Applied Mechanics,2015,32(6):1062-1068.
[2]KURRA S,RAHMAN N H,REGALLA S P,et al.Modeling and optimization of surface roughness in single point incremental forming process[J].Journal of Materials Research and Technology,2015,4(3):304-313.
[3]LU H,LI Y,DANIEL W J T,et al.Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology[J].International Journal of Advanced Manufacturing Technology,2015,79(9-12):2041-2055.
[4]RAJU C,HALOI N,NARAYANAN C S.Strain distribution and failure mode in single point incremental forming(SPIF)of multiple commercially pure aluminum sheets[J].Journal of Manufacturing Processes,2017,30:328-335.
[5]DAVARPANAH M A,ZHANG Z,BANSAL S,et al.Preliminary investigations on double sided incremental forming of thermoplastics[J].Manufacturing Letters,2016,8:21-26.
[6]李赳华,何凯,罗群,等.一种基于高压水射流的金属板材柔性渐进成形技术[J].集成技术,2012,1(3):42-46.LI Jiuhua,HE Kai,LUO Qun,et al.A new method for incremental sheet metal forming using water jet technology[J].Journal of Integration Technology,2012,1(3):42-46.
[7]LIU R,LU B,XU D,et al.Development of novel tools for electricity-assisted incremental sheet forming of titanium alloy[J].The International Journal of Advanced Manufacturing Technology,2016,85(5-8):1137-1144.
[8]MOHAMMADI A,VANHOVE H,BAEL A V,et al.Towards accuracy improvement in single point incremental forming of shallow parts formed under laser assisted conditions[J].International Journal of Material Forming,2016,9(3):339-351.
[9]GUAN Yanjin,XIE Zhendong,ZHAI Jiqiang,et al.Study on ultrasonic vibration assisted upsetting of 6063aluminum alloy[J].Procedia Engineering,2017,207:490-495.
[10]SAJJADY S A,ABADI H N H,AMINI S,et al.Analytical and experimental study of topography of surface texture in ultrasonic vibration assisted turning[J].Materials&Design,2016,93:311-323.
[11]MOLAIE M M,AKBARI J,MOVAHHEDY M R.Ultrasonic assisted grinding process with minimum quantity lubrication using oil-based nanofluids[J].Journal of Cleaner Production,2016,129:212-222.
[12]赵升吨李泳峄范淑琴.超声振动塑性加工技术的现状分析[J].中国机械工程,2013,24(6):835-840.ZHAO Shengdun,LI Yongyi,FAN Shuqin.Status analysis of plastic processing in technology with ultrasonic vibration[J].China Mechanical Engineering,2013,24(6):835-840
[13]MUNDO D,GATTI G,AMBROGIO G,et al.Considerations on process performance in incremental forming by inducing high frequency vibration[C]//Proceedings of EUCOMES 08.Springer Netherlands,2009:523-530.
[14]蔡改贫,张仲凯,姜志宏.金属板材振动单点渐进成形力学分析[J].机械科学与技术,2010,29(7):915-920.CAI Gaipin,ZHANG Zhongkai,JIANG Zhihong.Mechanical analysis of sheet metal vibration incremental forming[J].Mechanical Science and Technology for Aerospace Engineering,2010,29(7):915-920.
[15]VAHDATI M,MAHDAVINEJAD R,AMINI S.Investigation of the ultrasonic vibration effect in incremental sheet metal forming process[J].Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture,2015,231(6):971-982.
[16]AMINI S,GOLLO A H,PAKTINAT H.An investigation of conventional and ultrasonic-assisted incremental forming of annealed AA1050 sheet[J].The International Journal of Advanced Manufacturing Technology,2016,90(5-8):1-10.
[17]OBIKAWA T,HAYASHI M.Ultrasonic-assisted incremental microforming of thin shell pyramids of metallic foil[J].Micromachines,2017,8(5):142.
[18]CHEN Xiaoxiao,LI Yanle,SUN Jie,et al.Effects of ultrasonic vibration on deformation mechanism of incremental point-forming process[J].Procedia Engineering,2017,207:777-782.
[19]LI Pengyang,HE Jin,LIU Qiang,et al.Evaluation of forming forces in ultrasonic incremental sheet metal forming[J].Aerospace Science and Technology,2017,63:132-139.
[20]柏朗,李言,杨明顺,等.超声振动单点增量成形力研究[J].机械科学与技术,2018,37(2):270-275.BAI Lang,LI Yan,YANG Mingshun,et al.Research on forming force in single point incremental forming with ultrasonic vibration[J].Mechanical Science and Technology for Aerospace Engineering,2018,37(2):270-275.
[21]高永国,王德辉.1060铝合金动态力学性能的试验研究[J].工具技术,2015,49(10):48-51.GAO Yongguo,WANG Dehui.Investigation on dynamic mechanical properties of 1060 pure Aluminium[J].Tool Engineering,2015,49(10):48-51.
[22]李鹏阳,徐海峰,安武润,等.板料单点渐进成形力仿真与试验研究[J].应用力学学报,2015,32(6):1062-1068.LI Pengyang,XU Haifeng,AN Wurun,et al.Simulation and experimental study on single point incremental forming force of sheet[J].Chinese Journal of Applied Mechanics,2015,32(6):1062-1068.
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