金属板料数控渐进成形技术成形极限与回弹控制研究
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摘要
当前,由于产业发展的需要,许多新兴的加工技术应运而生,工业技术涉及到更为广泛的领域。虽然虚拟制造及优化技术得到广泛的关注,但原型制造却仍是必不可少的,传统制造技术只适合大规模、高产量的生产方式,但却不能满足越来越多的小批量、高精度或者快速原型制造产业的需求。因此迫切需要开发更具柔性的制造技术,其中就有这样一项技术,它可以满足成形出复杂型面的金属板料零件并保证其精度和表面粗糙度的前提下,还能大幅度降低模具成本以及减少对加工机床的依赖,这就是数控渐进成形(ISMF)。在数控渐进成形过程中,要得到所需的零件形状需要一套用于固定板料的成形装置、支撑板料的工具以及多样的成形头。本文通过大量实验总结出板料在数控渐进成形过程中的成形极限计算方法,以及回弹预测、控制和补偿手段,并得到成功验证,还加入人工智能神经网络和数值模拟技术力图减少实际生产中的试制次数,节约成本,缩短零件制造周期。
金属板料的厚度在数控渐进成形中受成形角度的影响很大,当板料加工中达到一定成形角度时就会发生破裂,经过试验发现,成形极限与料厚都与成形角度密切有关,而成形极限则是板料成形过程中是否发生破裂的标准,也即数控渐进成形能否成功衡量尺度。但是在实际测量板料变形后的料厚时由于测量手段及误差等因素的干扰往往得不到准确值,因此必须研究另一套预测方法,利用成形极限的“平均应变法”则提供了一种更好的选择。此外,另一个成形过程中的重要问题是回弹,要得到合格的零件必须在编制加工程序时对零件型面做相应的调整,这就是回弹控制与补偿,只有这样才能使零件型面与目标型面之间的误差达到最小,零件才算符合产品要求。针对以上介绍的对成形结果其中决定作用的两大因素——成形极限和回弹,必须分别制定解决策略才能打开数控渐进成形更广泛的应用前景。
而在解决破裂和回弹过程中都不约而同地用到型面重构,本文详细地介绍了几种型面重构方法的原理、用途和优缺点。而型面重构还为有限元数值模拟提供了必要的技术支撑。同时还就解决回弹问题用到的几种成形方式分别作了对比,详细论述地指出各种成形方法的用途,对制件成形质量的影响以及成本分析,为不同要求的制件提出综合指导意见。
本文最终的落脚点是通过实验及有限元数值模拟建立起一套预测、评价数控渐进成形能否将金属板料制成合格零件的知识系统,当预测在成形过程中会出现缺陷时能提供相应解决手段。所以综合运用了实验研究、理论推导、有限元数值模拟和人工智能神经网络构建数据库等多重手段,为预测、评价和解决板料在数控渐进成形过程中常见的问题提供了一套简单实用的工具。
Present day developing industries deal with a wide spectrum of components. In spite of extensive efforts being made with regards to virtual process optimizing technology, the production of prototype parts is still a necessity. The conventional means of manufacturing is suitable in case the required volume is high. If the demands are small in number or if it is a prototype component, the investment in tooling for such processes may not be justified. Therefore, it becomes imperative to explore new flexible manufacturing technologies. One such technology, which allows the production of complex parts by drastically reducing costs in tooling and in machinery, is Numerical Control Incremental Sheet Metal Forming (NCISMF). In NCISMF process, the desired shape is obtained using a fixed form defining support tool with an active small-size-forming tool, programmed to requirement. The aim of the presented dissertation is to optimize the NCISMF process through surface reconstruction after considering process-induced disturbances.
In NCISMF, the blank thickness, being the function of apex angle, is of significant influence, thereby arises the need to calculate a surface taking required final geometry and thickness influences into account. But by influences of error measurements, it is very hard to get the accurate thickness after proceesing. Therefore another measurement must be taken into considering, so the forming limit is a better choice. Additionally it is also necessary to consider spingback and make suitable adjustments in the surface so that the error between the produced geometry and required final geometry is minimal. Two separate custom-developed programs have to be developed to fulfill both the above requirements.
To solve the split and spingback, the surface reconstruction provides a good choice. Thus several methods of surface reconstruction principles are introduced in this paper by comparing advantages and disadvantages between each methods . The surface reconstruction provides the necessary technical support for the finite element numerical simulation (FEM) also. Farthemore to control springback several shaping methods are compared, respectively, the impact on the quality of workpiece and cost are analysisd by the use of various shaping methods. So it is a comprehensive guidance for forming workpieces with different requirements.
The ultimate focus is to gain knowledge by experiment and FEM to establish a set of forecasts, evaluation of NCISMF of sheet metal, that means the qualified parts can be achieved by the use of this knowledge system, and when defects come out this knowledge system can provide solutions during the forming process. Therefore, comprehensive use of the experimental study, theoretical analysis, numerical simulation and artificial neural networks, multi-database tools to predict, evaluate and solve the incremental sheet forming process in the NC common problem provides a simple and practical tool.
金属板料的厚度在数控渐进成形中受成形角度的影响很大,当板料加工中达到一定成形角度时就会发生破裂,经过试验发现,成形极限与料厚都与成形角度密切有关,而成形极限则是板料成形过程中是否发生破裂的标准,也即数控渐进成形能否成功衡量尺度。但是在实际测量板料变形后的料厚时由于测量手段及误差等因素的干扰往往得不到准确值,因此必须研究另一套预测方法,利用成形极限的“平均应变法”则提供了一种更好的选择。此外,另一个成形过程中的重要问题是回弹,要得到合格的零件必须在编制加工程序时对零件型面做相应的调整,这就是回弹控制与补偿,只有这样才能使零件型面与目标型面之间的误差达到最小,零件才算符合产品要求。针对以上介绍的对成形结果其中决定作用的两大因素——成形极限和回弹,必须分别制定解决策略才能打开数控渐进成形更广泛的应用前景。
而在解决破裂和回弹过程中都不约而同地用到型面重构,本文详细地介绍了几种型面重构方法的原理、用途和优缺点。而型面重构还为有限元数值模拟提供了必要的技术支撑。同时还就解决回弹问题用到的几种成形方式分别作了对比,详细论述地指出各种成形方法的用途,对制件成形质量的影响以及成本分析,为不同要求的制件提出综合指导意见。
本文最终的落脚点是通过实验及有限元数值模拟建立起一套预测、评价数控渐进成形能否将金属板料制成合格零件的知识系统,当预测在成形过程中会出现缺陷时能提供相应解决手段。所以综合运用了实验研究、理论推导、有限元数值模拟和人工智能神经网络构建数据库等多重手段,为预测、评价和解决板料在数控渐进成形过程中常见的问题提供了一套简单实用的工具。
Present day developing industries deal with a wide spectrum of components. In spite of extensive efforts being made with regards to virtual process optimizing technology, the production of prototype parts is still a necessity. The conventional means of manufacturing is suitable in case the required volume is high. If the demands are small in number or if it is a prototype component, the investment in tooling for such processes may not be justified. Therefore, it becomes imperative to explore new flexible manufacturing technologies. One such technology, which allows the production of complex parts by drastically reducing costs in tooling and in machinery, is Numerical Control Incremental Sheet Metal Forming (NCISMF). In NCISMF process, the desired shape is obtained using a fixed form defining support tool with an active small-size-forming tool, programmed to requirement. The aim of the presented dissertation is to optimize the NCISMF process through surface reconstruction after considering process-induced disturbances.
In NCISMF, the blank thickness, being the function of apex angle, is of significant influence, thereby arises the need to calculate a surface taking required final geometry and thickness influences into account. But by influences of error measurements, it is very hard to get the accurate thickness after proceesing. Therefore another measurement must be taken into considering, so the forming limit is a better choice. Additionally it is also necessary to consider spingback and make suitable adjustments in the surface so that the error between the produced geometry and required final geometry is minimal. Two separate custom-developed programs have to be developed to fulfill both the above requirements.
To solve the split and spingback, the surface reconstruction provides a good choice. Thus several methods of surface reconstruction principles are introduced in this paper by comparing advantages and disadvantages between each methods . The surface reconstruction provides the necessary technical support for the finite element numerical simulation (FEM) also. Farthemore to control springback several shaping methods are compared, respectively, the impact on the quality of workpiece and cost are analysisd by the use of various shaping methods. So it is a comprehensive guidance for forming workpieces with different requirements.
The ultimate focus is to gain knowledge by experiment and FEM to establish a set of forecasts, evaluation of NCISMF of sheet metal, that means the qualified parts can be achieved by the use of this knowledge system, and when defects come out this knowledge system can provide solutions during the forming process. Therefore, comprehensive use of the experimental study, theoretical analysis, numerical simulation and artificial neural networks, multi-database tools to predict, evaluate and solve the incremental sheet forming process in the NC common problem provides a simple and practical tool.
引文
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