A new unified constitutive model was developed to predict the two-stage creep-aging(TSCA)behavior of Al-Zn-Mg-Cu alloys.The particular bimodal precipitation feature was analyzed and modeled by considering the primary ...A new unified constitutive model was developed to predict the two-stage creep-aging(TSCA)behavior of Al-Zn-Mg-Cu alloys.The particular bimodal precipitation feature was analyzed and modeled by considering the primary micro-variables evolution at different temperatures and their interaction.The dislocation density was incorporated into the model to capture the effect of creep deformation on precipitation.Quantitative transmission electron microscopy and experimental data obtained from a previous study were used to calibrate the model.Subsequently,the developed constitutive model was implemented in the finite element(FE)software ABAQUS via the user subroutines for TSCA process simulation and the springback prediction of an integral panel.A TSCA test was performed.The result shows that the maximum radius deviation between the formed plate and the simulation results is less than 0.4 mm,thus validating the effectiveness of the developed constitutive model and FE model.展开更多
The bending springback of magnesium alloys is difficult to predict accurately by numerical simulations because of their anisotropic characteristics.The springback of magnesium alloy V-shaped roll-bending was analyzed ...The bending springback of magnesium alloys is difficult to predict accurately by numerical simulations because of their anisotropic characteristics.The springback of magnesium alloy V-shaped roll-bending was analyzed using the error optimization function in Matlab to optimize the anisotropic potential values required for the Hill’48 yield criterion in ABAQUS.The optimized Hill’48 yield criterion model was used to numerically simulate the springback of magnesium alloy V-shaped roll-bending.The simulation results were compared with the experimental results.Results show that the error between the springback change ratio obtained using the optimized Hill’48 yield criterion and experimentally formed parts is within 2%.Overall,the optimized Hill’48 yield criterion improves the prediction accuracy of springback in magnesium alloy V-shaped roll-bending.展开更多
Ti-Mo-O alloys were used to analyze the effect of Mo and O contents on the mechanical compatibility and biocompatibility.The bending modulus,bending yield strength and springback ratio of the alloys were evaluated by ...Ti-Mo-O alloys were used to analyze the effect of Mo and O contents on the mechanical compatibility and biocompatibility.The bending modulus,bending yield strength and springback ratio of the alloys were evaluated by using three-point bending tests and bending load-unloading tests.The biocompatibility was investigated by the adhesion,proliferation and the alkaline phosphatase(ALP)activity of mouse osteoblast-like cells(MC3T3-E1).The results showed that the bending modulus and bending yield strength first were increased and then decreased with the increase in Mo content,while the springback ratio exhibited an opposite trend to the bending modulus.With the increase in O content,the bending modulus remained almost constant,while the bending yield strength was increased.The springback ratio exhibited a similar trend to the bending yield strength.The in vitro biological experiments showed that the Ti-Mo-O alloys had excellent biocompatibility due to the formed stable oxide films on their surface.With the increase in O and Mo contents,the TiO_(2)-MoO_(2)oxide film became denser.Combining with mechanical compatibility and biocompatibility,the Ti-15Mo-0.2O and Ti-15Mo-0.3O alloys were more suitable for the biomedical application of spinal fixation device.展开更多
3D elastic-plastic FE model for simulating the force controlled stretch-bending process of double-cavity aluminum profile was established using hybrid explicit−implicit solvent method.Considering the computational acc...3D elastic-plastic FE model for simulating the force controlled stretch-bending process of double-cavity aluminum profile was established using hybrid explicit−implicit solvent method.Considering the computational accuracy and efficiency,the optimal choices of numerical parameters and algorithms in FE modelling were determined.The formation mechanisms of cross-section distortion and springback were revealed.The effects of pre-stretching,post-stretching,friction,and the addition of internal fillers on forming quality were investigated.The results show that the stress state of profile in stretch-bending is uniaxial with only a circumferential stress.The stress distribution along the length direction of profile is non-uniform and the maximum tensile stress is located at a certain distance away from the center of profile.As aluminum profile is gradually attached to bending die,the distribution characteristic of cross-section distortion along the length direction of profile changes from V-shape to W-shape.After unloading the forming tools,cross-section distortion decreases obviously due to the stress relaxation,with a maximum distortion difference of 13%before and after unloading.As pre-stretching and post-stretching forces increase,cross-section distortion increases gradually,while springback first decreases and then remains unchanged.With increasing friction between bending die and profile,cross-section distortion slightly decreases,while springback increases.Cross-section distortion decreases by 83%with adding PVC fillers into the cavities of profile,while springback increases by 192.2%.展开更多
A V-shaped bending device was established to evaluate the effects of temperature and bending fillet radius on springback behavior of 2219-W aluminum alloy at cryogenic temperatures.The cryogenic springback mechanism w...A V-shaped bending device was established to evaluate the effects of temperature and bending fillet radius on springback behavior of 2219-W aluminum alloy at cryogenic temperatures.The cryogenic springback mechanism was elucidated through mechanical analyses and numerical simulations.The results indicated that the springback angle at cryogenic temperatures was greater than that at room temperature.The springback angle increased further as the temperature returned to ambient conditions,attributed to the combined effects of the “dual enhancement effect” and thermal expansion.Notably,a critical fillet radius made the springback angle zero for 90° V-shaped bending.The critical fillet radius at cryogenic temperatures was smaller than that at room temperature,owing to the influence of temperature variations on the bending moment ratio between the forward bending section at the fillet and the reverse bending section of the straight arm.展开更多
To further investigate the forming mechanism and springback characteristics of strips under multi-square punch forming (MSPF) considering partial-unloading effects, a series of concave form ing tests of strips are con...To further investigate the forming mechanism and springback characteristics of strips under multi-square punch forming (MSPF) considering partial-unloading effects, a series of concave form ing tests of strips are conducted on the MSPF machine. This paper aims to reveal the physical mecha nism of the elastic-plastic deformation in the MSPF process considering the effect of the forming ap proaches, and derive appropriate mathematical interpretations. The theoretical model is firstly estab lished to analyse the concave forming mechanism and springback characteristics of the strip, and its accuracy is then validated by experimental data. The forming history and load evolutions are depicted to explore the required forming capacity through the proposed analytical method. Besides, the paramet ric studies are carried out to discuss their effects on the springback of the strip. The results suggest that the deformation paths of the strip are influenced by the forming approach, and the springback of the strip in convex forming is larger than that in concave forming.展开更多
In order to study the effects of the process parameters on springback and section deformation, a sensitivity analysis model was established based on the combination use of the multi-parameter sensitivity analysis meth...In order to study the effects of the process parameters on springback and section deformation, a sensitivity analysis model was established based on the combination use of the multi-parameter sensitivity analysis method and the springback/section deformation prediction finite element model, and by using this model the sensitivities of the springback and the section deformation to process parameters were analyzed and compared. The results show that the most sensitive process conditions for springback angle are the boost speed and the pressure of pressure die, and the most sensitive process condition for section deformation is the number of cores. When the clamp force, the boost speed and the pressure of pressure die are utilized to control section deformation, the effect of these process parameters on springback should be considered. When the process parameters are mainly used to control springback, the effect of these process parameters on the section deformation should be always considered.展开更多
In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath f...In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks （ANN） and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization （PSO） algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of s!oringback can be acquired using the FEM-PSONN model.展开更多
The theoretical analysis of springback in rotary stretch bending process of L-section extrusion was studied. The models for characterizing the springback angle after unloading were established based on the stress and ...The theoretical analysis of springback in rotary stretch bending process of L-section extrusion was studied. The models for characterizing the springback angle after unloading were established based on the stress and strain distributions in the cross-section of the part. With the proposed model, analysis of the effect of pre-stretch force and post-stretch force on springback angle shows that springback decreases as the pre-stretch force or post-stretch force increases. Comparative study with experiments clearly demonstrates that the prediction of springback can resort to the current model without the loss of accuracy.展开更多
The analysis of variance(ANOVA), multiple quadratic regression and radial basis function artificial neural network(RBFANN) methods were used to study the springback and tensile strength in age forming of 2A97 aluminum...The analysis of variance(ANOVA), multiple quadratic regression and radial basis function artificial neural network(RBFANN) methods were used to study the springback and tensile strength in age forming of 2A97 aluminum alloy based on orthogonal array. The ANOVA analysis indicates that the springback reaches the minimum value when age forming is performed at 210 °C for 20 h using a single-curvature die with a radius of 400 mm, and the tensile strength reaches the maximum value when age forming is performed at 180 °C for 15 h using a single-curvature die with a radius of 1000 mm. The orders of the importance for the three factors of pre-deformation radius, aging temperature and aging time on the springback and tensile strength were determined. By analyzing the predicted results of the multiple quadratic regression and RBFANN methods, the prediction accuracy of the RBFANN model is higher than that of the regression model.展开更多
The constitutive modeling and springback simulation for AA2524 sheet in creep age forming（CAF） process were presented.A series of creep aging tests were performed on AA2524 at the temperature of 180-200 °C and ...The constitutive modeling and springback simulation for AA2524 sheet in creep age forming（CAF） process were presented.A series of creep aging tests were performed on AA2524 at the temperature of 180-200 °C and under the stress of 140-210 MPa for 16 h.Based on these experimental data,material constitutive equations which can well characterize creep aging behaviors of the tested alloy were developed.The effect of interior stress distributed along the sheet thickness on springback was simulated using FE software MSC.MARC by compiling the established constitutive models into the user subroutine.The simulation results showed that the amount of sheet springback was 61.12% when merely considering tensile stress existing along the sheet thickness;while sheet springback was up to 65.93% when taking both tensile and compressive stresses into account.In addition,an AA2524 rectangular sheet was subjected to CAF experiment in resistance furnace.The springback value of the formed rectangular sheet was 68.2%,which was much closer to 65.93%.This confirms that both tensile and compressive stresses across the sheet thickness should be considered in accurately predicting springback of the sheet after forming,which can be more consistent with experimental results.展开更多
Significant springback occurs after tube rotary-draw-bending （RDB）, especially for a high-strength Ti-3A1-2.5V tube （HSTT） due to its high ratio of yield strength to Young＇s modulus. The combination scheme of exp...Significant springback occurs after tube rotary-draw-bending （RDB）, especially for a high-strength Ti-3A1-2.5V tube （HSTT） due to its high ratio of yield strength to Young＇s modulus. The combination scheme of explicit and implicit is preferred to predict the springback. This simulation strategy includes several numerical parameters, such as element type, number of elements through thickness （NEL）, element size, etc. However, the influences of these parameters on spring- back prediction accuracy are not fully understood. Thus, taking the geometrical specification 9.525 mm × 0.508 mm ofa HSTT as the objective, the effects of numerical parameters on prediction accuracy and computation efficiency of springback simulation of HSTT RDB are investigated. The simulated springback results are compared with experimental ones. The main results are： （1） solid and continuum-shell elements predict the experimental results well; （2） for C3DSR elements, NEL of at least 3 is required to obtain reliable results and a relative error of 29% can occur as NEL is varied in the range of 1-3; （3） specifying damping factor typically works well in Abaqus/Emplicit simulation of springback and the springback results are sensitive to the magnitude of damping factor. In addition, the explanations of the effect rules are given and a guideline is added.展开更多
Springback behavior of 6016 aluminum alloy in hot stamping was investigated by a series of experiments under different conditions using V-shape dies and a finite element model which was validated reliable was used to ...Springback behavior of 6016 aluminum alloy in hot stamping was investigated by a series of experiments under different conditions using V-shape dies and a finite element model which was validated reliable was used to further elucidate the springback mechanism. The effects of initial blank temperature, blank-holding force, die closing pressure and die corner radius were studied. It is found that springback decreases remarkably as the initial blank temperature rises up to 500 °C. The springback also reduces with the increase of die holding pressure and the decrease of die corner radius. Under different initial temperatures, the influence of blank-holding force is distinct. In addition, the bending and straightening of the side wall during the stamping process is found to interpret the negative springback phenomenon.展开更多
Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work.The sensitivity analysis was pro...Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work.The sensitivity analysis was provided to have an insight in the effect of the evaluated process parameters.Furthermore,in order to minimize the springback problem,an accurate springback simulation model of the part was established and validated.The effects of the element size and timesteps on springback model were further investigated.Results indicate that the custom mesh size is beneficial for the springback simulation,and the four timesteps are found suited for the springback analysis for the complex geometry part.Finally,a strategy for reducing the springback by changing the geometry of the blank is proposed.The optimal blank geometry is obtained and used for manufacturing the part.展开更多
Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plan...Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plane strain condition, an analytical model is proposed in this paper which takes into account the effects of contact pressure, the length of bending arm between the punch and die, transverse stress, neutral surface shifting and sheet thickness thinning on the sheet springback of V-bending. The predicted results by this analytical model indicated that the contact pressure and transverse stress have much effect on the springback when the bending ratio (the ratio of punch radius to sheet thickness) is less than five. The contact pressure declined when the length of bending arm goes up, which means that shorter length of bending arm will result in larger springback. The effect of neutral surface shifting on the springback is less than that of contact pressure and decreases with the bending ratio. However, this research showed that the influence of thickness thinning on the springback can be ignored. Comparison with finite element method (FEM) simu-lating results shows that the predicted results by the analytical model accord well with simulation results by FEM. In addition to that, the bending ability—the limit bending ratio for a given sheet thickness and material properties was also determined.展开更多
Most of the existing studies use constant force to reduce springback while researching stretch force. However, variable stretch force can reduce springback more efficiently. The current research on springback predicti...Most of the existing studies use constant force to reduce springback while researching stretch force. However, variable stretch force can reduce springback more efficiently. The current research on springback prediction in stretch bending forming mainly focuses on artificial neural networks combined with the finite element simulation. There is a lack of springback prediction by support vector regression（SVR）. In this paper, SVR is applied to predict springback in the three-dimensional stretch bending forming process, and variable stretch force trajectory is optimized. Six parameters of variable stretch force trajectory are chosen as the input parameters of the SVR model. Sixty experiments generated by design of experiments（DOE） are carried out to train and test the SVR model. The experimental results confirm that the accuracy of the SVR model is higher than that of artificial neural networks. Based on this model, an optimization algorithm of variable stretch force trajectory using particle swarm optimization（PSO） is proposed. The springback amount is used as the objective function. Changes of local thickness are applied as the criterion of forming constraints. The objection and constraints are formulated by response surface models. The precision of response surface models is examined. Six different stretch force trajectories are employed to certify springback reduction in the optimum stretch force trajectory, which can efficiently reduce springback. This research proposes a new method of springback prediction using SVR and optimizes variable stretch force trajectory to reduce springback.展开更多
Creep age forming(CAF)is an advanced forming technology that combines creep deformation and age hardening processes.When compared with the conventional forming technologies including roll bending and shot-peen forming...Creep age forming(CAF)is an advanced forming technology that combines creep deformation and age hardening processes.When compared with the conventional forming technologies including roll bending and shot-peen forming,CAF has many advantages of low residual stress,excellent dimensional stability,good service performance and short production cycle.It is an optimal technique for precise manufacturing for shape and properties of large-scale complicated thinwalled components of light-weight and high strength aluminum alloys in the aviation and aerospace industries.Nevertheless,CAF has an inevitable disadvantage that a large amount of springback occurs after unloading,which brings a challenge on the accurate shape forming and property tailoring of components.Therefore,how to achieve accurate prediction and control of springback has always been a bottleneck hindering the development of CAF to more industrial applications.After the factors of affecting springback and measures of reducing springback are summarized from the internal and external aspects,constitutive models for predicting springback and springback compensation methods for CAF of aluminum alloy panel components are reviewed.Then,a review of research progresses on tool design for CAF is presented.Finally,in view of the key issue that it is difficult to predict and control the shape and properties of components during CAF,the technical challenges are discussed and future development trends of CAF are prospected.展开更多
In this paper,the springback of TC4 titanium alloy under hot stamping condition was studied by means of experiment and numerical analysis.Firstly,an analytical model was established to predict the V-shaped springback ...In this paper,the springback of TC4 titanium alloy under hot stamping condition was studied by means of experiment and numerical analysis.Firstly,an analytical model was established to predict the V-shaped springback angleΔαunder the stretch-bending conditions.The model took into account of blank holder force,friction,property of the material,thickness of the sheet and the neutral layer shift.Then,the influence of several process parameters on springback was studied by experiment and finite element simulation using a V-shaped stamping tool.In the hot stamping tests,the titanium alloy sheet fractured seriously at room temperature.The titanium alloy has good formability when the initial temperature of the sheet is 750–900°C.However,the springback angle of formed parts is large and decreases with increasing temperature.The springback angleΔαdecreased by 50%from 0.5°to 0.25°,and the angleΔβdecreased by 46.7%from 1.5°to 0.8°when the initial temperature of sheet increased from 750°C to 900°C.The springback angle of titanium alloy sheet increases gradually with the increase of the punch radius,because of the increase of elastic recovery,the complex distribution of stress,the length of forming region and the decreasing degree of stress.Compared with the simulation results,the analytical model can better predict the springback angleΔα.展开更多
Three dimensional(3D)tubes,which possess the characteristics of space saving,lightweight and high strength,are widely used in many high-end industries such as aviation,aerospace,automobile and shipbuilding.However,whe...Three dimensional(3D)tubes,which possess the characteristics of space saving,lightweight and high strength,are widely used in many high-end industries such as aviation,aerospace,automobile and shipbuilding.However,when manufacturing a 3D tube in flexible bending process,springback is a big obstacle for improving the forming quality.In this paper,a new comprehensive strategy for springback control of 3D tubes is proposed.The strategy can be described as follows:(1)define the desired shape and manufacture shape;(2)optimize the manufacture shape using two tooling design methods(e.g.DA(displacement adjustment)method and B&T(bending and twisting)method presented in this paper);(3)make a discretization of the manufacture shape to acquire the optimized forming parameters.Additionally,experiment is implemented to validate the effectiveness of the new strategy.Results show that forming parameters acquired by the new strategy are partially effective.The new strategy also demonstrates that,during 3D tubes forming,the deviation caused by over-bent elements can be counteracted by the deficient-bent elements.This principle is helpful to reduce the difficulty of parameter determination in future.展开更多
The analytical model for springback in arc bending of sheet metal can serve as an excellent design support.The amount of springback is considerably influenced by the geometrical and the material parameters associated ...The analytical model for springback in arc bending of sheet metal can serve as an excellent design support.The amount of springback is considerably influenced by the geometrical and the material parameters associated with the sheet metal.In addition,the applied load during the bending also has a significant influence.Although a number of numerical techniques have been used for this purpose,only few analytical models that can provide insight into the phenomenon are available.A phenomenological model for predicting the springback in arc bending was proposed based on strain as well as deformation energy based approaches.The results of the analytical model were compared with the published experimental as well as FE results of the authors,and the agreement was found to be satisfactory.展开更多
基金supported by the National Key R&D Program of China(No.2021YFB3400900)the National Natural Science Foundation of China(Nos.52175373,52205435)+1 种基金Natural Science Foundation of Hunan Province,China(No.2022JJ40621)the Innovation Fund of National Commercial Aircraft Manufacturing Engineering Technology Center,China(No.COMACSFGS-2022-1875)。
文摘A new unified constitutive model was developed to predict the two-stage creep-aging(TSCA)behavior of Al-Zn-Mg-Cu alloys.The particular bimodal precipitation feature was analyzed and modeled by considering the primary micro-variables evolution at different temperatures and their interaction.The dislocation density was incorporated into the model to capture the effect of creep deformation on precipitation.Quantitative transmission electron microscopy and experimental data obtained from a previous study were used to calibrate the model.Subsequently,the developed constitutive model was implemented in the finite element(FE)software ABAQUS via the user subroutines for TSCA process simulation and the springback prediction of an integral panel.A TSCA test was performed.The result shows that the maximum radius deviation between the formed plate and the simulation results is less than 0.4 mm,thus validating the effectiveness of the developed constitutive model and FE model.
基金National Natural Science Foundation of China(52274389)Key Research and Development Plan of Shanxi Province(202102010101010,202202150401010)+3 种基金Science and Technology Activities for Overseas Students Selected Funding Project of Shanxi Province(20220028)Raise Funds to Help Returnees of Shanxi Province(2022-160)National Natural Science Foundation of China(Youth Science Foundation Project)(52004169)Returnee Research Support Project of Shanxi Province(2021-132)。
文摘The bending springback of magnesium alloys is difficult to predict accurately by numerical simulations because of their anisotropic characteristics.The springback of magnesium alloy V-shaped roll-bending was analyzed using the error optimization function in Matlab to optimize the anisotropic potential values required for the Hill’48 yield criterion in ABAQUS.The optimized Hill’48 yield criterion model was used to numerically simulate the springback of magnesium alloy V-shaped roll-bending.The simulation results were compared with the experimental results.Results show that the error between the springback change ratio obtained using the optimized Hill’48 yield criterion and experimentally formed parts is within 2%.Overall,the optimized Hill’48 yield criterion improves the prediction accuracy of springback in magnesium alloy V-shaped roll-bending.
基金supported by the National Natural Science Foundation of China(Grant No.52071051)the(Key)Foundation of Xi'an Key Laboratory of High-Performance Titanium Alloy(No.NIN-HTL-2022-ZD01).
文摘Ti-Mo-O alloys were used to analyze the effect of Mo and O contents on the mechanical compatibility and biocompatibility.The bending modulus,bending yield strength and springback ratio of the alloys were evaluated by using three-point bending tests and bending load-unloading tests.The biocompatibility was investigated by the adhesion,proliferation and the alkaline phosphatase(ALP)activity of mouse osteoblast-like cells(MC3T3-E1).The results showed that the bending modulus and bending yield strength first were increased and then decreased with the increase in Mo content,while the springback ratio exhibited an opposite trend to the bending modulus.With the increase in O content,the bending modulus remained almost constant,while the bending yield strength was increased.The springback ratio exhibited a similar trend to the bending yield strength.The in vitro biological experiments showed that the Ti-Mo-O alloys had excellent biocompatibility due to the formed stable oxide films on their surface.With the increase in O and Mo contents,the TiO_(2)-MoO_(2)oxide film became denser.Combining with mechanical compatibility and biocompatibility,the Ti-15Mo-0.2O and Ti-15Mo-0.3O alloys were more suitable for the biomedical application of spinal fixation device.
基金the National Natural Science Foundation of China(Nos.52005244,U20A20275)the Natural Science Foundation of Hunan Province,China(Nos.2021JJ30573,2023JJ60193)the Open Fund of State Key Laboratory of Advanced Design and Manufacture for Vehicle Body,China(No.31715011)。
文摘3D elastic-plastic FE model for simulating the force controlled stretch-bending process of double-cavity aluminum profile was established using hybrid explicit−implicit solvent method.Considering the computational accuracy and efficiency,the optimal choices of numerical parameters and algorithms in FE modelling were determined.The formation mechanisms of cross-section distortion and springback were revealed.The effects of pre-stretching,post-stretching,friction,and the addition of internal fillers on forming quality were investigated.The results show that the stress state of profile in stretch-bending is uniaxial with only a circumferential stress.The stress distribution along the length direction of profile is non-uniform and the maximum tensile stress is located at a certain distance away from the center of profile.As aluminum profile is gradually attached to bending die,the distribution characteristic of cross-section distortion along the length direction of profile changes from V-shape to W-shape.After unloading the forming tools,cross-section distortion decreases obviously due to the stress relaxation,with a maximum distortion difference of 13%before and after unloading.As pre-stretching and post-stretching forces increase,cross-section distortion increases gradually,while springback first decreases and then remains unchanged.With increasing friction between bending die and profile,cross-section distortion slightly decreases,while springback increases.Cross-section distortion decreases by 83%with adding PVC fillers into the cavities of profile,while springback increases by 192.2%.
基金the financial supports from the National Key Research and Development Program of China (No. 2019YFA0708804)。
文摘A V-shaped bending device was established to evaluate the effects of temperature and bending fillet radius on springback behavior of 2219-W aluminum alloy at cryogenic temperatures.The cryogenic springback mechanism was elucidated through mechanical analyses and numerical simulations.The results indicated that the springback angle at cryogenic temperatures was greater than that at room temperature.The springback angle increased further as the temperature returned to ambient conditions,attributed to the combined effects of the “dual enhancement effect” and thermal expansion.Notably,a critical fillet radius made the springback angle zero for 90° V-shaped bending.The critical fillet radius at cryogenic temperatures was smaller than that at room temperature,owing to the influence of temperature variations on the bending moment ratio between the forward bending section at the fillet and the reverse bending section of the straight arm.
文摘To further investigate the forming mechanism and springback characteristics of strips under multi-square punch forming (MSPF) considering partial-unloading effects, a series of concave form ing tests of strips are conducted on the MSPF machine. This paper aims to reveal the physical mecha nism of the elastic-plastic deformation in the MSPF process considering the effect of the forming ap proaches, and derive appropriate mathematical interpretations. The theoretical model is firstly estab lished to analyse the concave forming mechanism and springback characteristics of the strip, and its accuracy is then validated by experimental data. The forming history and load evolutions are depicted to explore the required forming capacity through the proposed analytical method. Besides, the paramet ric studies are carried out to discuss their effects on the springback of the strip. The results suggest that the deformation paths of the strip are influenced by the forming approach, and the springback of the strip in convex forming is larger than that in concave forming.
基金Project (50975235) supported by the National Natural Science Foundation of ChinaProject (B08040) supported by the 111 Project
文摘In order to study the effects of the process parameters on springback and section deformation, a sensitivity analysis model was established based on the combination use of the multi-parameter sensitivity analysis method and the springback/section deformation prediction finite element model, and by using this model the sensitivities of the springback and the section deformation to process parameters were analyzed and compared. The results show that the most sensitive process conditions for springback angle are the boost speed and the pressure of pressure die, and the most sensitive process condition for section deformation is the number of cores. When the clamp force, the boost speed and the pressure of pressure die are utilized to control section deformation, the effect of these process parameters on springback should be considered. When the process parameters are mainly used to control springback, the effect of these process parameters on the section deformation should be always considered.
基金Project(50175034) supported by the National Natural Science Foundation of China
文摘In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks （ANN） and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization （PSO） algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of s!oringback can be acquired using the FEM-PSONN model.
基金Project (20090450276) supported by the China Postdoctoral Science FoundationProject (50905008) supported by the National Natural Science Foundation of China
文摘The theoretical analysis of springback in rotary stretch bending process of L-section extrusion was studied. The models for characterizing the springback angle after unloading were established based on the stress and strain distributions in the cross-section of the part. With the proposed model, analysis of the effect of pre-stretch force and post-stretch force on springback angle shows that springback decreases as the pre-stretch force or post-stretch force increases. Comparative study with experiments clearly demonstrates that the prediction of springback can resort to the current model without the loss of accuracy.
文摘The analysis of variance(ANOVA), multiple quadratic regression and radial basis function artificial neural network(RBFANN) methods were used to study the springback and tensile strength in age forming of 2A97 aluminum alloy based on orthogonal array. The ANOVA analysis indicates that the springback reaches the minimum value when age forming is performed at 210 °C for 20 h using a single-curvature die with a radius of 400 mm, and the tensile strength reaches the maximum value when age forming is performed at 180 °C for 15 h using a single-curvature die with a radius of 1000 mm. The orders of the importance for the three factors of pre-deformation radius, aging temperature and aging time on the springback and tensile strength were determined. By analyzing the predicted results of the multiple quadratic regression and RBFANN methods, the prediction accuracy of the RBFANN model is higher than that of the regression model.
基金Project(2014CB046602)supported by the National Basic Research Program of ChinaProject(20120162110003)supported by Ph D Programs Foundation of Ministry of Education of China
文摘The constitutive modeling and springback simulation for AA2524 sheet in creep age forming（CAF） process were presented.A series of creep aging tests were performed on AA2524 at the temperature of 180-200 °C and under the stress of 140-210 MPa for 16 h.Based on these experimental data,material constitutive equations which can well characterize creep aging behaviors of the tested alloy were developed.The effect of interior stress distributed along the sheet thickness on springback was simulated using FE software MSC.MARC by compiling the established constitutive models into the user subroutine.The simulation results showed that the amount of sheet springback was 61.12% when merely considering tensile stress existing along the sheet thickness;while sheet springback was up to 65.93% when taking both tensile and compressive stresses into account.In addition,an AA2524 rectangular sheet was subjected to CAF experiment in resistance furnace.The springback value of the formed rectangular sheet was 68.2%,which was much closer to 65.93%.This confirms that both tensile and compressive stresses across the sheet thickness should be considered in accurately predicting springback of the sheet after forming,which can be more consistent with experimental results.
基金the National Natural Science Foundation of China (No.51275415)Program for New Century Excellent Talents in University+1 种基金the fund of the State Key Laboratory of Solidifcation Processing in NWPUNatural Science Basic Research Plan in Shaanxi Province (No.2011JQ6004),and the 111 Project (No.B08040) for the support
文摘Significant springback occurs after tube rotary-draw-bending （RDB）, especially for a high-strength Ti-3A1-2.5V tube （HSTT） due to its high ratio of yield strength to Young＇s modulus. The combination scheme of explicit and implicit is preferred to predict the springback. This simulation strategy includes several numerical parameters, such as element type, number of elements through thickness （NEL）, element size, etc. However, the influences of these parameters on spring- back prediction accuracy are not fully understood. Thus, taking the geometrical specification 9.525 mm × 0.508 mm ofa HSTT as the objective, the effects of numerical parameters on prediction accuracy and computation efficiency of springback simulation of HSTT RDB are investigated. The simulated springback results are compared with experimental ones. The main results are： （1） solid and continuum-shell elements predict the experimental results well; （2） for C3DSR elements, NEL of at least 3 is required to obtain reliable results and a relative error of 29% can occur as NEL is varied in the range of 1-3; （3） specifying damping factor typically works well in Abaqus/Emplicit simulation of springback and the springback results are sensitive to the magnitude of damping factor. In addition, the explanations of the effect rules are given and a guideline is added.
基金Projects(U1564202,51705018)supported by the National Natural Science Foundation of ChinaProject(FRF-TP-15-087A1)supported by the Fundamental Research Funds for the Central Universities,China
文摘Springback behavior of 6016 aluminum alloy in hot stamping was investigated by a series of experiments under different conditions using V-shape dies and a finite element model which was validated reliable was used to further elucidate the springback mechanism. The effects of initial blank temperature, blank-holding force, die closing pressure and die corner radius were studied. It is found that springback decreases remarkably as the initial blank temperature rises up to 500 °C. The springback also reduces with the increase of die holding pressure and the decrease of die corner radius. Under different initial temperatures, the influence of blank-holding force is distinct. In addition, the bending and straightening of the side wall during the stamping process is found to interpret the negative springback phenomenon.
基金Project(2014ZX04002041)supported by the National Science and Technology Major Project,ChinaProject(51175024)supported by the National Natural Science Foundation of China
文摘Springback of a SUS321 complex geometry part formed by the multi-stage rigid-flexible compound process was studied through numerical simulations and laboratory experiments in this work.The sensitivity analysis was provided to have an insight in the effect of the evaluated process parameters.Furthermore,in order to minimize the springback problem,an accurate springback simulation model of the part was established and validated.The effects of the element size and timesteps on springback model were further investigated.Results indicate that the custom mesh size is beneficial for the springback simulation,and the four timesteps are found suited for the springback analysis for the complex geometry part.Finally,a strategy for reducing the springback by changing the geometry of the blank is proposed.The optimal blank geometry is obtained and used for manufacturing the part.
文摘Springback is caused by the redistribution of stress in sheet material after the tooling is removed. Precise prediction of sheet springback is very important in die design. Based on Hill’s yielding criterion and plane strain condition, an analytical model is proposed in this paper which takes into account the effects of contact pressure, the length of bending arm between the punch and die, transverse stress, neutral surface shifting and sheet thickness thinning on the sheet springback of V-bending. The predicted results by this analytical model indicated that the contact pressure and transverse stress have much effect on the springback when the bending ratio (the ratio of punch radius to sheet thickness) is less than five. The contact pressure declined when the length of bending arm goes up, which means that shorter length of bending arm will result in larger springback. The effect of neutral surface shifting on the springback is less than that of contact pressure and decreases with the bending ratio. However, this research showed that the influence of thickness thinning on the springback can be ignored. Comparison with finite element method (FEM) simu-lating results shows that the predicted results by the analytical model accord well with simulation results by FEM. In addition to that, the bending ability—the limit bending ratio for a given sheet thickness and material properties was also determined.
基金Supported by National Technical Innovation Foundation of China(Grant No.Jilin Province 350)
文摘Most of the existing studies use constant force to reduce springback while researching stretch force. However, variable stretch force can reduce springback more efficiently. The current research on springback prediction in stretch bending forming mainly focuses on artificial neural networks combined with the finite element simulation. There is a lack of springback prediction by support vector regression（SVR）. In this paper, SVR is applied to predict springback in the three-dimensional stretch bending forming process, and variable stretch force trajectory is optimized. Six parameters of variable stretch force trajectory are chosen as the input parameters of the SVR model. Sixty experiments generated by design of experiments（DOE） are carried out to train and test the SVR model. The experimental results confirm that the accuracy of the SVR model is higher than that of artificial neural networks. Based on this model, an optimization algorithm of variable stretch force trajectory using particle swarm optimization（PSO） is proposed. The springback amount is used as the objective function. Changes of local thickness are applied as the criterion of forming constraints. The objection and constraints are formulated by response surface models. The precision of response surface models is examined. Six different stretch force trajectories are employed to certify springback reduction in the optimum stretch force trajectory, which can efficiently reduce springback. This research proposes a new method of springback prediction using SVR and optimizes variable stretch force trajectory to reduce springback.
基金financial support from the Key Program of the National Natural Science Foundation of China (No.51235010)the National Science Fund for Excellent Young Scholars (No.51522509)the National Natural Science Foundation of China (NO.51905424)
文摘Creep age forming(CAF)is an advanced forming technology that combines creep deformation and age hardening processes.When compared with the conventional forming technologies including roll bending and shot-peen forming,CAF has many advantages of low residual stress,excellent dimensional stability,good service performance and short production cycle.It is an optimal technique for precise manufacturing for shape and properties of large-scale complicated thinwalled components of light-weight and high strength aluminum alloys in the aviation and aerospace industries.Nevertheless,CAF has an inevitable disadvantage that a large amount of springback occurs after unloading,which brings a challenge on the accurate shape forming and property tailoring of components.Therefore,how to achieve accurate prediction and control of springback has always been a bottleneck hindering the development of CAF to more industrial applications.After the factors of affecting springback and measures of reducing springback are summarized from the internal and external aspects,constitutive models for predicting springback and springback compensation methods for CAF of aluminum alloy panel components are reviewed.Then,a review of research progresses on tool design for CAF is presented.Finally,in view of the key issue that it is difficult to predict and control the shape and properties of components during CAF,the technical challenges are discussed and future development trends of CAF are prospected.
基金Projects(U1564202,51705018)supported by the National Natural Science Foundation of ChinaProject supported by the Beijing Laboratory of Modern Transportation Metal Materials and Processing Technology and the Beijing Key Laboratory of Metal Forming Lightweight,China。
文摘In this paper,the springback of TC4 titanium alloy under hot stamping condition was studied by means of experiment and numerical analysis.Firstly,an analytical model was established to predict the V-shaped springback angleΔαunder the stretch-bending conditions.The model took into account of blank holder force,friction,property of the material,thickness of the sheet and the neutral layer shift.Then,the influence of several process parameters on springback was studied by experiment and finite element simulation using a V-shaped stamping tool.In the hot stamping tests,the titanium alloy sheet fractured seriously at room temperature.The titanium alloy has good formability when the initial temperature of the sheet is 750–900°C.However,the springback angle of formed parts is large and decreases with increasing temperature.The springback angleΔαdecreased by 50%from 0.5°to 0.25°,and the angleΔβdecreased by 46.7%from 1.5°to 0.8°when the initial temperature of sheet increased from 750°C to 900°C.The springback angle of titanium alloy sheet increases gradually with the increase of the punch radius,because of the increase of elastic recovery,the complex distribution of stress,the length of forming region and the decreasing degree of stress.Compared with the simulation results,the analytical model can better predict the springback angleΔα.
基金supported by Key Research and Development Program of Shaanxi of China(No.2020ZDLGY01-05)。
文摘Three dimensional(3D)tubes,which possess the characteristics of space saving,lightweight and high strength,are widely used in many high-end industries such as aviation,aerospace,automobile and shipbuilding.However,when manufacturing a 3D tube in flexible bending process,springback is a big obstacle for improving the forming quality.In this paper,a new comprehensive strategy for springback control of 3D tubes is proposed.The strategy can be described as follows:(1)define the desired shape and manufacture shape;(2)optimize the manufacture shape using two tooling design methods(e.g.DA(displacement adjustment)method and B&T(bending and twisting)method presented in this paper);(3)make a discretization of the manufacture shape to acquire the optimized forming parameters.Additionally,experiment is implemented to validate the effectiveness of the new strategy.Results show that forming parameters acquired by the new strategy are partially effective.The new strategy also demonstrates that,during 3D tubes forming,the deviation caused by over-bent elements can be counteracted by the deficient-bent elements.This principle is helpful to reduce the difficulty of parameter determination in future.
文摘The analytical model for springback in arc bending of sheet metal can serve as an excellent design support.The amount of springback is considerably influenced by the geometrical and the material parameters associated with the sheet metal.In addition,the applied load during the bending also has a significant influence.Although a number of numerical techniques have been used for this purpose,only few analytical models that can provide insight into the phenomenon are available.A phenomenological model for predicting the springback in arc bending was proposed based on strain as well as deformation energy based approaches.The results of the analytical model were compared with the published experimental as well as FE results of the authors,and the agreement was found to be satisfactory.
