Taking half-tube part with curvature as an example,the Impact Hydroforming(IHF)characteristics were studied by combining the actual forming experiment and numerical simulation.The IHF experiment showed that wrinkles a...Taking half-tube part with curvature as an example,the Impact Hydroforming(IHF)characteristics were studied by combining the actual forming experiment and numerical simulation.The IHF experiment showed that wrinkles appeared at the bottom of the part during single-step forming,but no wrinkles were observed during double-step forming.The thinning rate and deviation of the wall thickness of the part in each area were less than 20%and 2.7 mm,correspondingly,and the drawing depth of the part reached 45.8 mm.The effect of double-step forming was better than that of single-step forming,which was related to the IHF forming law.Besides,the characteristics of the IHF process were studied by numerical simulation.The results indicated that when double-step forming was utilized,there was almost no velocity field in the opposite direction of deformation after the bottom of the part contacted the die,and the existence of stress state at the bottom would restrain and eliminate the wrinkles.The inertia effect evolved with the driving pressure.Specially,the inertia effect can improve the flow of metal and reduce the deviation of the wall thickness of the part under double-step forming.展开更多
The multi-pass intermittent local loading process,which features a more flexible processing path,can further enhance the second material distribution during local loading,improve the formability of components,and redu...The multi-pass intermittent local loading process,which features a more flexible processing path,can further enhance the second material distribution during local loading,improve the formability of components,and reduce forming loads.However,the absence of compatible forming equipment makes it difficult to control the constraint in the unloaded zones during the forming process.This difficulty complicates coordination and control of deformation,particularly for asymmetric rib-web components.Additionally,the current implementation involves multi-fire heating,a long process flow,and high energy consumption,which limits the popularization and application of the local loading process.In this study,a new multi-pass local loading hydraulic forming apparatus that can quickly and reliably switch between heavy-load deformation and low-load constraint for different local loading sub-dies was developed.A 10-tonne laboratory prototype was developed,and the forming characteristics during the forming process as well as the response characteristics of the hydraulic system during the multi-pass intermittent local loading of rib-web component were investigated using numerical simulations and physical experiments.Results indicated that,compared to a whole loading process with the same initial geometry of billet,the total forming load(i.e.,the sum of loaded and restrained loads)is reduced by more than 40%with the local loading process,and by nearly 50%with multi-pass local loading.The multi-pass local loading process allows for more effective control of material flow compared to single-pass local loading,leading to improved cavity filling and reduced flow line disturbance.For a large-scale,complex titanium alloy bulkhead,the cavity filling problem was addressed by optimizing the multi-pass local loading path with an unequal thickness billet.The dynamic performance of the multi-pass local loading hydraulic system was found to be robust,with stable pressure transitions during motion and load switching for the sub-die(s).The dynamic characteristic of the hydraulic cylinder when switching from non-moving/unloaded state to a moving/loading state are consistent whether a load is present or not.However,the dynamic characteristics differ when switching from a moving/loading state to non-moving/unloaded state,showing opposite behavior.The developed hydraulic drive mechanism provides a way for implementation of multi-pass local loading without auxiliary operation and extra heating.The results of the study provide a foundation for the industrial production of large-scale,complex components with reduced force requirement and low-energy consumption.展开更多
A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which ca...A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which can accurately describe the strain and stress states in IF.Based on strain analysis,the model can predict the material thickness distribution and neck height after IF.By considering contact area,strain characteristics,material thickness changes,and friction,the model can predict specific moments and corresponding values of maximum axial forming force and maximum horizontal forming force during IF.In addition,an IF experiment involving different tool diameters,flanging diameters,and opening hole diameters is conducted.On the basis of the experimental strain paths,the strain characteristics of different deformation zones are studied,and the stable strain ratio is quantitatively described through two dimensionless parameters:relative tool diameter and relative hole diameter.Then,the changing of material thickness and forming force in IF,and the variation of minimum material thickness,neck height,maximum axial forming force,and maximum horizontal forming force with flanging parameters are studied,and the reliability of the analytical model is verified in this process.Finally,the influence of the horizontal forming force on the tool design and the fluctuation of the forming force are explained.展开更多
To achieve the manufacturing of Thin-Wall and High-Rib Components(TWHRC)with high precision,a novel heavy load Multi-DOF Envelope Forming Press(MEFP)with Parallel Kinematic Mechanism(PKM),driven by six Permanent Magne...To achieve the manufacturing of Thin-Wall and High-Rib Components(TWHRC)with high precision,a novel heavy load Multi-DOF Envelope Forming Press(MEFP)with Parallel Kinematic Mechanism(PKM),driven by six Permanent Magnet Synchronous Motors(PMSMs),is developed.However,on account of the heavy forming load,the PMSM parameters are in great variation.Meanwhile,the PMSM is always in a transient state caused by fast time-varying forming load,resulting in low identification precision of varied PMSM parameters and control precision of PMSM under traditional parameter identification methods.To solve this problem,a novel Sliding Mode Control Method with Enhanced PMSM Parameter Identification(SMCMEPPI)for heavy load MEFP is proposed.Firstly,the kinematic model of MEFP is established.Secondly,the variation law of PMSM parameters under heavy load is revealed.Thirdly,an enhanced PMSM parameter identification method is proposed,in which the q axis current of PMSM is used to represent the changing rate of forming load and the adjustment factor is first proposed to remove improper input of PMSM parameter identification online.Fourthly,the Electromechanical Coupling Dynamic Model(ECDM)of MEFP,which includes identified PMSM parameters,is developed.Finally,based on the developed ECDM,a novel SMCMEPPI is proposed to realize the high-precision control of heavy load MEFP.The experimental results indicate that the proposed SMCMEPPI can significantly improve the control precision of heavy load MEFP.展开更多
Tube thinning control without wrinkling occurring is a key problem urgently to be solved for improving the forming qualities in numerical control （NC） bending processes of large-diameter Al-alloy thin-walled tubes ...Tube thinning control without wrinkling occurring is a key problem urgently to be solved for improving the forming qualities in numerical control （NC） bending processes of large-diameter Al-alloy thin-walled tubes （AATTs）. It may be a way solving this problem to exert axial compression loads （ACL） on the tube end in the bending. Thus, this article establishes a three-dimensional （3D） elastic-plastic explicit finite element （FE） model for the bending under ACL and has its reliability verified. Through a multi-index orthogonal experiment design, a combination of process parameters, each expressed by a proper range, for this FE model is derived to overcome the compression instability on tube ends. By combining the FE model with a wrinkling energy prediction model, an in-depth study is conducted on the forming characteristics of large-diameter AATTs with small bending radii and it can be concluded that （1） The larger the tube diameters and the smaller the bending radii, the larger the induced tangent tension stress zones on tube intrados, by which the tube maximum tangent compression stress zones will be partitioned in the bending processes; thus, the smaller the ACL roles in decreasing thinning degrees and the larger the compression instability possibilities on tube ends. （2） The tube wrinkling possibilities under ACL are larger than without ACL acting in the earlier forming periods, and smaller in the later ones. （3） For the tubes with a size factor less than 80, the ACL roles in decreasing thinning degrees are stronger than in increasing wrinkling possibilities.展开更多
In order to find out the optimal press bend forming path in fabricating aircraft integral panels, this article proposes a new method on the basis of the authors＇ previous work. It is composed of the finite element me...In order to find out the optimal press bend forming path in fabricating aircraft integral panels, this article proposes a new method on the basis of the authors＇ previous work. It is composed of the finite element method （FEM） equivalent model, the surface curvature analysis, the artificial neural network response surface and the genetic algorithm. The method begins with analyzing the objective＇s shape curvature to determine the bending position. Then it optimizes the punch travel at each bending position by the following steps： （1） Establish a multi-step press bend forming FEM equivalent model, with which the FEM ex- periments designed with the Taguchi method are performed. （2） Construct a back-propagation （BP） neural network response surface with the data from the FEM experiments. （3） Use the genetic algorithm to optimize the neural network response surface as the objective function. Finally, this method is verified by press bending a complicated double-curvature grid-type stiffened panel and bears out its effectiveness and intrinsic worth in designing the press bend forming path.展开更多
A theoretical prediction on forming limit diagram（FLD） of AZ31 magnesium alloy sheet was developed at warm temperatures based on the M-K theory. Two different yield criteria of von Mises and Hill＇48 were applied in...A theoretical prediction on forming limit diagram（FLD） of AZ31 magnesium alloy sheet was developed at warm temperatures based on the M-K theory. Two different yield criteria of von Mises and Hill＇48 were applied in this model. Mechanical properties of AZ31 magnesium alloy used in the prediction were obtained by uniaxial tensile tests and the Fields-Backofen equation was incorporated in the analysis. In addition, experimental FLDs of AZ31 were acquired by conducting rigid die swell test at different temperatures to verify the prediction. It is demonstrated from a comparison between the predicted and the experimental FLDs at 473 K and 523 K that the predicted results are influenced by the type of yield criterion used in the calculation, especially at lower temperatures. Furthermore, a better agreement between the predicted results and experimental data for AZ31 magnesium alloy sheet at warm temperatures was obtained when Hill＇48 yield criterion was applied.展开更多
A new technological process of tube forming was developed, namely solution treatment → granule medium internal high pressure forming → artificial aging. During this process, the mechanical properties of AA6061 tube ...A new technological process of tube forming was developed, namely solution treatment → granule medium internal high pressure forming → artificial aging. During this process, the mechanical properties of AA6061 tube can be adjusted by heat treatment to satisfy the process requirements and the processing method can also be realized by granule medium internal high pressure forming technology with the features of convenient implementation, low requirement to equipment and flexible design in product. Results show that, at a solution temperature of 560 ℃ and time of 120 min, the elongation of AA6061 increases by 313%, but the strength and the hardness dramatically decrease. At an aging temperature of 180 ℃ and time of 360 min, the strength and hardness of AA6061 alloy are recovered to the values of the as-received alloy. The maximum expansion ratio（MER） of AA6061 tube increases by 25.5% and the material properties of formed tube reach the performances of raw material.展开更多
In order to predict the buckling of stiffeners in the press bend forming of the integral panel,a method for solving the critical buckling load of the stiffeners in press bend forming process was proposed based on ener...In order to predict the buckling of stiffeners in the press bend forming of the integral panel,a method for solving the critical buckling load of the stiffeners in press bend forming process was proposed based on energy method,elastic-plastic mechanics and numerical analysis.Bend to buckle experiments were carried out on the designed press bend dies.It is found that the predicted results based on the proposed method agree well with the experimental results.With the proposed method,the buckling of the stiffeners in press bend forming of the aluminum alloy integral panels with high-stiffener can be predicted reasonably.展开更多
The granule medium of discreteness is supposed to be continuous（Drucker-Prager model） in the existing finite element simulation analysis on the hot granule medium pressure forming（HGMF） process, so the granule med...The granule medium of discreteness is supposed to be continuous（Drucker-Prager model） in the existing finite element simulation analysis on the hot granule medium pressure forming（HGMF） process, so the granule medium may produce tensile stress in the process of pressure-transferring and flowing, which does not coincide with the reality. The analysis method, discrete element and finite element（DE-FE） coupling simulation, is proposed to solve the problem. The material parameters of simulation model are obtained by the pressure-transfer performance test of granule medium and the hot uniaxial tensile test of sheet metal. The DE-FE coupling simulation platform is established by adopting Visual Basic language. The features in the process that AA7075-T6 conical parts are formed by the HGMF process are analyzed and verified by the process test. The studies show that the results of DE-FE coupling simulation coincide well with the test results, which provides a new analysis method to solve the mechanics problem in the coupling of discrete and continuum.展开更多
A combined method of selective laser sintering （SLS） and cold isostatic pressing （CIP） was applied to manufacturing metal parts rapidly. Finite element method was used to predict final dimensions and decrease cost...A combined method of selective laser sintering （SLS） and cold isostatic pressing （CIP） was applied to manufacturing metal parts rapidly. Finite element method was used to predict final dimensions and decrease cost. The simulations of CIP of selective laser sintered parts were carried out by Drucker-Prager-Cap constitutive model with ABAQUS computer program. The property of metal powder was measured by CIP experiments. The results show the rubber bag and the friction coefficient have little influence on results of simulations. The parts only have uniform shrinkage and have no obvious distortion in shape. The results of simulations show a good agreement with the experimental results and the calculated results, indicating that the Drucker-Prager-Cap model is an effective model to simulate CIP process. The simulations could give a useful direction to forming process of the CIP of selective laser sintered components. K展开更多
Wrinkling is a common failure in the sheet metal forming of titanium owing to the relatively poor ability to shrink. It is important to predict wrinkling accurately in the sheet metal forming without costly trials. Th...Wrinkling is a common failure in the sheet metal forming of titanium owing to the relatively poor ability to shrink. It is important to predict wrinkling accurately in the sheet metal forming without costly trials. The ABAQUS/Explicit code was utilized to predict the wrinkling behavior in the sheet metal forming of Ti-15-3 alloy sheets. In terms of the comparison of wrinkling behavior between the simulation and experiment of the Fukui＇s conical cup tests at room temperature, the sensitivities of wrinkling simulation to various input parameters were evaluated comprehensively and quantitatively. Prediction of wrinkling and influence of rubber hardness on the winkling behavior in the rubber forming of convex flange were investigated quantitatively and validated by the rubber forming experiments. The excellent agreements between the simulations and the experiments conIirmed the accuracy of the prediction.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
A novel process for manufacturing A1-0.70Fe-0.24Cu alloy conductor was proposed, which includes horizontal continuous casting and subsequent continuous extrusion forming （Conform）. The mechanical properties, electri...A novel process for manufacturing A1-0.70Fe-0.24Cu alloy conductor was proposed, which includes horizontal continuous casting and subsequent continuous extrusion forming （Conform）. The mechanical properties, electrical conductivity and the compressed creep behaviour of the alloy were studied. The results indicate that the Conform process induces obvious grain refinement, strain-induced precipitation of AI7CuzFe phase and the transformation of crystal orientation distribution. The processed alloy has good comprehensive mechanical properties and electrical conductivity. Moreover, a better creep resistance under the conditions of 90 ~C and 76 MPa is shown compared with pure A1 and annealed copper, and the relationship between primary creep strain and time may comply with the logarithmic law. The enhanced properties are attributed to the grain refinement as well as the fine and homogeneously distributed thermally stable A1Fe and A17Cu2Fe precipitation phases.展开更多
High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing ...High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing flexible mould forming process, the heat resistance of the medium and pressurizing device makes the application of aluminum alloy plate thermoforming restricted. To solve this problem, the existing medium is replaced by the heat-resisting solid granules and the general pressure equipments are applied. Based on the pressure-transfer performance test of the solid granules medium, the feasibility that the assumption of the extended Drucker-Prager linear model can be used in the finite element analysis is proved. The constitutive equation, the yield function and the theoretical forming limit diagram（FLD） of AA7075 sheet are established. Through the finite element numerical simulation of hot granules medium pressure forming（HGMF） process, not only the influence laws of the process parameters, such as forming temperature, the blank-holder gap and the diameter of the slab, on sheet metal forming performance are discussed, but also the broken area of the forming process is analyzed and predicted, which are coincided with the technological test. The conical part whose half cone angle is 15° and relative height H/d0 is 0.57, is formed in one process at 250℃. The HGMF process solves the problems of loading and seal in the existing flexible mould forming process and provides a novel technology for thermoforming of light alloy plate, such as magnesium alloy, aluminium alloy and titanium alloy.展开更多
The conventional forming limit diagram （FLD） is described as a plot of major strain versus minor strain. However, FLD is dependent on forming history and strain path. In the present study, a forming limit stress-bas...The conventional forming limit diagram （FLD） is described as a plot of major strain versus minor strain. However, FLD is dependent on forming history and strain path. In the present study, a forming limit stress-based diagram （FLSD） has been adopted to predict the fracture limit of aluminum alloy （AA） 5052-O1 sheet. Nakazima test is simulated by plastic constitutive formula derived from the modified Gurson-Tvergaard-Needleman （GTN） model. An in situ tensile test with scanning electron microscope （SEM） is proposed to determine the parameters in GTN model. The damage evolution is observed and recorded, and the parameters of GTN model are identified through counting void fraction at three damage stages of AA5052-O 1. According to the experimental results, the original void volume fraction, the volume fraction of potential nucleated voids, the critical void volume fraction, the void volume fraction at the final failure of material are assigned as 0.002 918, 0.024 9, 0.030 103, 0.048 54, respectively. The stress and strain are obtained at the last loading step before crack. FLSD and FLD of AA5052-O 1 are plotted. Compared with the experimental Nakazima test and uniaxial tensile test, the predicted results show a good agreement. The parameters determined by in situ tensile test can be applied to the research of the forming limit for ductile metals.展开更多
Based on the combination of materials science and mechanical engineering,hot press forming process of the vehicle high strength steels was analyzed. The hot forming process included：heating alloys rapidly to austenit...Based on the combination of materials science and mechanical engineering,hot press forming process of the vehicle high strength steels was analyzed. The hot forming process included：heating alloys rapidly to austenite microstructures,stamping and cooling timely,maintaining pressure and quenching. The results showed that most of austenite microstructure was changed into uniform martensite by the hot press forming while the samples were heated at 900 ℃ and quenched. The optimal tensile strength and yield strength were up to 1530 MPa and 1000 MPa,respectively,and the shape deformation reached about 23%. And springback defect did not happen in the samples.展开更多
Plane strain assumption and exponent hardening law are used to investigate the plastic deformation in tube bending. Some theoretical formulae including stress, curvature radius of neutral layer, angle of neutral layer...Plane strain assumption and exponent hardening law are used to investigate the plastic deformation in tube bending. Some theoretical formulae including stress, curvature radius of neutral layer, angle of neutral layer deviation, bending moment, wall thickness variation and crosssection distortion, are developed to explain the phenomena in tube bending and their magnitudes are also determined. During unloading process, the springback angle is deduced using the virtual work principle, and springback radius is also given according to the length of the neutral layer which remains unchanged before and after springback. The theoretical formulae are validated by the experimental results or the validated simulation results in literature, which can be used to auicklv predict the forming aualitv of tube numerical control （NC） bending.展开更多
The exploration targets in the Kuqa Depression at present are mainly structure traps in Cretaceous-Tertiary.Due to the complexity of mountain distribution and reservoir forming conditions, the exploration of Jurassic ...The exploration targets in the Kuqa Depression at present are mainly structure traps in Cretaceous-Tertiary.Due to the complexity of mountain distribution and reservoir forming conditions, the exploration of Jurassic in the eastern Kuqa Depression has been in a state of semi-stagnation since the discovery of the Yinan-2 gas reservoir.According to the concept and theory of 'continuous petroleum reservoirs' and the re-analysis of the forming conditions of the Yinan-2 gas reservoir and regional natural gas in the eastern Kuqa Depression,it is believed that the deep Jurassic has good natural gas accumulation conditions as well as geological conditions for forming continuous tight gas reservoirs.The boundary of the Yinan-2 gas reservoir is not controlled by a structural spillpoint.The downdip part of the structure is dominated by gas,while the hanging wall of the fault is filled by water and forming obvious inverted gas and water.The gas reservoir has the normal temperature and ultrahigh pressure which formed in the near source or inner-source.All of these characteristics indicate that the Yinan-2 gas reservoir is different from conventional gas reservoirs.The deep Jurassic in the eastern Kuqa Depression has multisets of source-reservoir-cap assemblages,which comprise interbedded sandstones and mudstones.These assemblages are characterized by a self-generation,self-preserving and self-coverage model.Reservoir sandstones and coal measure mudstones are interbedded with each other at a large scale.As the source rocks,Triassic-Jurassic coal measure mudstones distribute continuously at a large scale and can generate and expel hydrocarbon.Source rocks contact intimately with the overlying sandstone reservoirs.During the late stage of hydrocarbon expulsion,natural gas charged continuously and directly into the neighboring reservoirs.Petroleum migrated mainly in a vertical direction over short distances.With ultra-high pressure and strong charging intensity,natural gas accumulated continuously.Reservoirs are dominated by sandstones of braided delta facies.The sand bodies distribute continuously horizontal.With low porosity and low permeability,the reservoirs are featured by strong heterogeneity.It is hypothesized that the sandstones of the interior depression tend to be relatively tight with increasing depth and structure stress weakness.Thus,it is predicted that continuous tight gas reservoirs of ultra-high pressure may exist in the deep formations of the eastern and even the whole Kuqa Depression.So,it is worth evaluating the exploration potential.展开更多
The precision forming of thin-walled components has been urgently needed in aviation and aerospace field. However, the wrinkling induced by the compressive instability is one of the major defects in thin-walled part f...The precision forming of thin-walled components has been urgently needed in aviation and aerospace field. However, the wrinkling induced by the compressive instability is one of the major defects in thin-walled part forming. The initiation and growth of the wrinkles are interac- tively affected by many factors such as stress states, mechanical properties of the material, geometry of the workpiece and boundary conditions. Especially when the forming process involves compli- cated boundary conditions such as multi-dies constrains, the perturbation of clearances between workpiece and dies and the contact conditions changing in time and space, etc., the predication of the wrinkling is further complicated. In this paper, the cu.rent prediction methods were summa- rized including the static equilibrium method, the energy method, the initial imperfection method, the eigenvalue buckling analysis method, the static-implicit finite element method and the dynamic- explicit finite element method. Then, a systematical comparison and summary of these methods in terms of their advantages and limitations are presented. By using a combination of explicit FE method, initial imperfection and energy conservation, a hybrid method is recommended to predict plastic wrinkling in thin-walled part forming. Finally, considering the urgent requirements of com- plex thin-walled structures＇ part in aviation and aerospace field, the trends and challenges in wrin- kling prediction under complicated boundary conditions are presented.展开更多
基金financially supported by the National Key R&D Program of China(No.2024YFE0108800/T24KITG014)the National Natural Science Foundation of China(No:52475411)the International Partnership Program of Chinese Academy of Sciences(No.172GJHZ2022096FN)。
文摘Taking half-tube part with curvature as an example,the Impact Hydroforming(IHF)characteristics were studied by combining the actual forming experiment and numerical simulation.The IHF experiment showed that wrinkles appeared at the bottom of the part during single-step forming,but no wrinkles were observed during double-step forming.The thinning rate and deviation of the wall thickness of the part in each area were less than 20%and 2.7 mm,correspondingly,and the drawing depth of the part reached 45.8 mm.The effect of double-step forming was better than that of single-step forming,which was related to the IHF forming law.Besides,the characteristics of the IHF process were studied by numerical simulation.The results indicated that when double-step forming was utilized,there was almost no velocity field in the opposite direction of deformation after the bottom of the part contacted the die,and the existence of stress state at the bottom would restrain and eliminate the wrinkles.The inertia effect evolved with the driving pressure.Specially,the inertia effect can improve the flow of metal and reduce the deviation of the wall thickness of the part under double-step forming.
基金the supports of the National Natural Science Foundation of China(Grant No.52375378)。
文摘The multi-pass intermittent local loading process,which features a more flexible processing path,can further enhance the second material distribution during local loading,improve the formability of components,and reduce forming loads.However,the absence of compatible forming equipment makes it difficult to control the constraint in the unloaded zones during the forming process.This difficulty complicates coordination and control of deformation,particularly for asymmetric rib-web components.Additionally,the current implementation involves multi-fire heating,a long process flow,and high energy consumption,which limits the popularization and application of the local loading process.In this study,a new multi-pass local loading hydraulic forming apparatus that can quickly and reliably switch between heavy-load deformation and low-load constraint for different local loading sub-dies was developed.A 10-tonne laboratory prototype was developed,and the forming characteristics during the forming process as well as the response characteristics of the hydraulic system during the multi-pass intermittent local loading of rib-web component were investigated using numerical simulations and physical experiments.Results indicated that,compared to a whole loading process with the same initial geometry of billet,the total forming load(i.e.,the sum of loaded and restrained loads)is reduced by more than 40%with the local loading process,and by nearly 50%with multi-pass local loading.The multi-pass local loading process allows for more effective control of material flow compared to single-pass local loading,leading to improved cavity filling and reduced flow line disturbance.For a large-scale,complex titanium alloy bulkhead,the cavity filling problem was addressed by optimizing the multi-pass local loading path with an unequal thickness billet.The dynamic performance of the multi-pass local loading hydraulic system was found to be robust,with stable pressure transitions during motion and load switching for the sub-die(s).The dynamic characteristic of the hydraulic cylinder when switching from non-moving/unloaded state to a moving/loading state are consistent whether a load is present or not.However,the dynamic characteristics differ when switching from a moving/loading state to non-moving/unloaded state,showing opposite behavior.The developed hydraulic drive mechanism provides a way for implementation of multi-pass local loading without auxiliary operation and extra heating.The results of the study provide a foundation for the industrial production of large-scale,complex components with reduced force requirement and low-energy consumption.
基金supported in part by financial support from the National Key R&D Program of China(No.2023YFB3407003)the National Natural Science Foundation of China(No.52375378).
文摘A new analytical model for geometric size and forming force prediction in incremental flanging(IF)is presented in this work.The complex deformation characteristics of IF are considered in the modeling process,which can accurately describe the strain and stress states in IF.Based on strain analysis,the model can predict the material thickness distribution and neck height after IF.By considering contact area,strain characteristics,material thickness changes,and friction,the model can predict specific moments and corresponding values of maximum axial forming force and maximum horizontal forming force during IF.In addition,an IF experiment involving different tool diameters,flanging diameters,and opening hole diameters is conducted.On the basis of the experimental strain paths,the strain characteristics of different deformation zones are studied,and the stable strain ratio is quantitatively described through two dimensionless parameters:relative tool diameter and relative hole diameter.Then,the changing of material thickness and forming force in IF,and the variation of minimum material thickness,neck height,maximum axial forming force,and maximum horizontal forming force with flanging parameters are studied,and the reliability of the analytical model is verified in this process.Finally,the influence of the horizontal forming force on the tool design and the fluctuation of the forming force are explained.
基金the National Science and Technology Major Project of China(No.2019-Ⅶ-0017-0158)the National Natural Science Foundation of China(Nos.U2037204,U21A20131)the Innovative Research Team Development Program of Ministry of Education of China(No.IRT17R83)for the support given to this research。
文摘To achieve the manufacturing of Thin-Wall and High-Rib Components(TWHRC)with high precision,a novel heavy load Multi-DOF Envelope Forming Press(MEFP)with Parallel Kinematic Mechanism(PKM),driven by six Permanent Magnet Synchronous Motors(PMSMs),is developed.However,on account of the heavy forming load,the PMSM parameters are in great variation.Meanwhile,the PMSM is always in a transient state caused by fast time-varying forming load,resulting in low identification precision of varied PMSM parameters and control precision of PMSM under traditional parameter identification methods.To solve this problem,a novel Sliding Mode Control Method with Enhanced PMSM Parameter Identification(SMCMEPPI)for heavy load MEFP is proposed.Firstly,the kinematic model of MEFP is established.Secondly,the variation law of PMSM parameters under heavy load is revealed.Thirdly,an enhanced PMSM parameter identification method is proposed,in which the q axis current of PMSM is used to represent the changing rate of forming load and the adjustment factor is first proposed to remove improper input of PMSM parameter identification online.Fourthly,the Electromechanical Coupling Dynamic Model(ECDM)of MEFP,which includes identified PMSM parameters,is developed.Finally,based on the developed ECDM,a novel SMCMEPPI is proposed to realize the high-precision control of heavy load MEFP.The experimental results indicate that the proposed SMCMEPPI can significantly improve the control precision of heavy load MEFP.
基金National Natural Science Foundation of China (59975076, 50175092)National Science Fund of China for Distinguished Young Scholars (50225518)
文摘Tube thinning control without wrinkling occurring is a key problem urgently to be solved for improving the forming qualities in numerical control （NC） bending processes of large-diameter Al-alloy thin-walled tubes （AATTs）. It may be a way solving this problem to exert axial compression loads （ACL） on the tube end in the bending. Thus, this article establishes a three-dimensional （3D） elastic-plastic explicit finite element （FE） model for the bending under ACL and has its reliability verified. Through a multi-index orthogonal experiment design, a combination of process parameters, each expressed by a proper range, for this FE model is derived to overcome the compression instability on tube ends. By combining the FE model with a wrinkling energy prediction model, an in-depth study is conducted on the forming characteristics of large-diameter AATTs with small bending radii and it can be concluded that （1） The larger the tube diameters and the smaller the bending radii, the larger the induced tangent tension stress zones on tube intrados, by which the tube maximum tangent compression stress zones will be partitioned in the bending processes; thus, the smaller the ACL roles in decreasing thinning degrees and the larger the compression instability possibilities on tube ends. （2） The tube wrinkling possibilities under ACL are larger than without ACL acting in the earlier forming periods, and smaller in the later ones. （3） For the tubes with a size factor less than 80, the ACL roles in decreasing thinning degrees are stronger than in increasing wrinkling possibilities.
基金Specialized Research Fund for the Doctoral Program of High Education of China (20091102110021)
文摘In order to find out the optimal press bend forming path in fabricating aircraft integral panels, this article proposes a new method on the basis of the authors＇ previous work. It is composed of the finite element method （FEM） equivalent model, the surface curvature analysis, the artificial neural network response surface and the genetic algorithm. The method begins with analyzing the objective＇s shape curvature to determine the bending position. Then it optimizes the punch travel at each bending position by the following steps： （1） Establish a multi-step press bend forming FEM equivalent model, with which the FEM ex- periments designed with the Taguchi method are performed. （2） Construct a back-propagation （BP） neural network response surface with the data from the FEM experiments. （3） Use the genetic algorithm to optimize the neural network response surface as the objective function. Finally, this method is verified by press bending a complicated double-curvature grid-type stiffened panel and bears out its effectiveness and intrinsic worth in designing the press bend forming path.
基金Project(51375328)supported by the National Natural Science Foundation of ChinaProject(20143009)supported by Graduates Innovation Project of Shanxi Province,ChinaProject(2015-036)supported by Shanxi Scholarship Council of China
文摘A theoretical prediction on forming limit diagram（FLD） of AZ31 magnesium alloy sheet was developed at warm temperatures based on the M-K theory. Two different yield criteria of von Mises and Hill＇48 were applied in this model. Mechanical properties of AZ31 magnesium alloy used in the prediction were obtained by uniaxial tensile tests and the Fields-Backofen equation was incorporated in the analysis. In addition, experimental FLDs of AZ31 were acquired by conducting rigid die swell test at different temperatures to verify the prediction. It is demonstrated from a comparison between the predicted and the experimental FLDs at 473 K and 523 K that the predicted results are influenced by the type of yield criterion used in the calculation, especially at lower temperatures. Furthermore, a better agreement between the predicted results and experimental data for AZ31 magnesium alloy sheet at warm temperatures was obtained when Hill＇48 yield criterion was applied.
基金Project(51775481)supported by the National Natural Science Foundation of ChinaProject(A2016002017)supported by the High-level Talents Program of Heibei Province,China
文摘A new technological process of tube forming was developed, namely solution treatment → granule medium internal high pressure forming → artificial aging. During this process, the mechanical properties of AA6061 tube can be adjusted by heat treatment to satisfy the process requirements and the processing method can also be realized by granule medium internal high pressure forming technology with the features of convenient implementation, low requirement to equipment and flexible design in product. Results show that, at a solution temperature of 560 ℃ and time of 120 min, the elongation of AA6061 increases by 313%, but the strength and the hardness dramatically decrease. At an aging temperature of 180 ℃ and time of 360 min, the strength and hardness of AA6061 alloy are recovered to the values of the as-received alloy. The maximum expansion ratio（MER） of AA6061 tube increases by 25.5% and the material properties of formed tube reach the performances of raw material.
基金Project (51005010) supported by the National Natural Science Foundation of ChinaProject (20091102110021) supported by the Specialized Research Fund for the Doctoral Program of High Education of China
文摘In order to predict the buckling of stiffeners in the press bend forming of the integral panel,a method for solving the critical buckling load of the stiffeners in press bend forming process was proposed based on energy method,elastic-plastic mechanics and numerical analysis.Bend to buckle experiments were carried out on the designed press bend dies.It is found that the predicted results based on the proposed method agree well with the experimental results.With the proposed method,the buckling of the stiffeners in press bend forming of the aluminum alloy integral panels with high-stiffener can be predicted reasonably.
基金Projects(5130538651305385)supported by the National Natural Science Foundation of China+1 种基金Project(E2013203093)supported by the Natural Science Foundation of Hebei ProvinceChina
文摘The granule medium of discreteness is supposed to be continuous（Drucker-Prager model） in the existing finite element simulation analysis on the hot granule medium pressure forming（HGMF） process, so the granule medium may produce tensile stress in the process of pressure-transferring and flowing, which does not coincide with the reality. The analysis method, discrete element and finite element（DE-FE） coupling simulation, is proposed to solve the problem. The material parameters of simulation model are obtained by the pressure-transfer performance test of granule medium and the hot uniaxial tensile test of sheet metal. The DE-FE coupling simulation platform is established by adopting Visual Basic language. The features in the process that AA7075-T6 conical parts are formed by the HGMF process are analyzed and verified by the process test. The studies show that the results of DE-FE coupling simulation coincide well with the test results, which provides a new analysis method to solve the mechanics problem in the coupling of discrete and continuum.
基金Project(2007AA03Z115) supported by the High-Tech Research and Development Program of China
文摘A combined method of selective laser sintering （SLS） and cold isostatic pressing （CIP） was applied to manufacturing metal parts rapidly. Finite element method was used to predict final dimensions and decrease cost. The simulations of CIP of selective laser sintered parts were carried out by Drucker-Prager-Cap constitutive model with ABAQUS computer program. The property of metal powder was measured by CIP experiments. The results show the rubber bag and the friction coefficient have little influence on results of simulations. The parts only have uniform shrinkage and have no obvious distortion in shape. The results of simulations show a good agreement with the experimental results and the calculated results, indicating that the Drucker-Prager-Cap model is an effective model to simulate CIP process. The simulations could give a useful direction to forming process of the CIP of selective laser sintered components. K
文摘Wrinkling is a common failure in the sheet metal forming of titanium owing to the relatively poor ability to shrink. It is important to predict wrinkling accurately in the sheet metal forming without costly trials. The ABAQUS/Explicit code was utilized to predict the wrinkling behavior in the sheet metal forming of Ti-15-3 alloy sheets. In terms of the comparison of wrinkling behavior between the simulation and experiment of the Fukui＇s conical cup tests at room temperature, the sensitivities of wrinkling simulation to various input parameters were evaluated comprehensively and quantitatively. Prediction of wrinkling and influence of rubber hardness on the winkling behavior in the rubber forming of convex flange were investigated quantitatively and validated by the rubber forming experiments. The excellent agreements between the simulations and the experiments conIirmed the accuracy of the prediction.
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(20130161110007) supported by the Doctoral Program of Higher Education of China
文摘A novel process for manufacturing A1-0.70Fe-0.24Cu alloy conductor was proposed, which includes horizontal continuous casting and subsequent continuous extrusion forming （Conform）. The mechanical properties, electrical conductivity and the compressed creep behaviour of the alloy were studied. The results indicate that the Conform process induces obvious grain refinement, strain-induced precipitation of AI7CuzFe phase and the transformation of crystal orientation distribution. The processed alloy has good comprehensive mechanical properties and electrical conductivity. Moreover, a better creep resistance under the conditions of 90 ~C and 76 MPa is shown compared with pure A1 and annealed copper, and the relationship between primary creep strain and time may comply with the logarithmic law. The enhanced properties are attributed to the grain refinement as well as the fine and homogeneously distributed thermally stable A1Fe and A17Cu2Fe precipitation phases.
基金Supported by National Natural Science Foundation of China(Grant Nos.51305386,51305385)Hebei Provincial Natural Science Foundation of China(Grant No.E2013203093)
文摘High strength aluminum alloy plate has a low elongation at room temperature, which leads to the forming of its components need a high temperature. Liquid or gas is used as the pressure-transfer medium in the existing flexible mould forming process, the heat resistance of the medium and pressurizing device makes the application of aluminum alloy plate thermoforming restricted. To solve this problem, the existing medium is replaced by the heat-resisting solid granules and the general pressure equipments are applied. Based on the pressure-transfer performance test of the solid granules medium, the feasibility that the assumption of the extended Drucker-Prager linear model can be used in the finite element analysis is proved. The constitutive equation, the yield function and the theoretical forming limit diagram（FLD） of AA7075 sheet are established. Through the finite element numerical simulation of hot granules medium pressure forming（HGMF） process, not only the influence laws of the process parameters, such as forming temperature, the blank-holder gap and the diameter of the slab, on sheet metal forming performance are discussed, but also the broken area of the forming process is analyzed and predicted, which are coincided with the technological test. The conical part whose half cone angle is 15° and relative height H/d0 is 0.57, is formed in one process at 250℃. The HGMF process solves the problems of loading and seal in the existing flexible mould forming process and provides a novel technology for thermoforming of light alloy plate, such as magnesium alloy, aluminium alloy and titanium alloy.
基金Aeronautical Science Foundation of China （03H53048）
文摘The conventional forming limit diagram （FLD） is described as a plot of major strain versus minor strain. However, FLD is dependent on forming history and strain path. In the present study, a forming limit stress-based diagram （FLSD） has been adopted to predict the fracture limit of aluminum alloy （AA） 5052-O1 sheet. Nakazima test is simulated by plastic constitutive formula derived from the modified Gurson-Tvergaard-Needleman （GTN） model. An in situ tensile test with scanning electron microscope （SEM） is proposed to determine the parameters in GTN model. The damage evolution is observed and recorded, and the parameters of GTN model are identified through counting void fraction at three damage stages of AA5052-O 1. According to the experimental results, the original void volume fraction, the volume fraction of potential nucleated voids, the critical void volume fraction, the void volume fraction at the final failure of material are assigned as 0.002 918, 0.024 9, 0.030 103, 0.048 54, respectively. The stress and strain are obtained at the last loading step before crack. FLSD and FLD of AA5052-O 1 are plotted. Compared with the experimental Nakazima test and uniaxial tensile test, the predicted results show a good agreement. The parameters determined by in situ tensile test can be applied to the research of the forming limit for ductile metals.
基金Item Sponsored by National Natural Science Foundation of China (50901011)National Science Fund for Distinguished Young Scholars of China (10125208)Liaoning Province Doctor Startup Fund of China (20071090)
文摘Based on the combination of materials science and mechanical engineering,hot press forming process of the vehicle high strength steels was analyzed. The hot forming process included：heating alloys rapidly to austenite microstructures,stamping and cooling timely,maintaining pressure and quenching. The results showed that most of austenite microstructure was changed into uniform martensite by the hot press forming while the samples were heated at 900 ℃ and quenched. The optimal tensile strength and yield strength were up to 1530 MPa and 1000 MPa,respectively,and the shape deformation reached about 23%. And springback defect did not happen in the samples.
基金the National Natural Science Foundation of China (No.51164030)National Defense Key Disciplines Laboratory of Light Alloy Processing Science and Technology, Nanchang Hangkong University (No.gf201501001) for the support on this research
文摘Plane strain assumption and exponent hardening law are used to investigate the plastic deformation in tube bending. Some theoretical formulae including stress, curvature radius of neutral layer, angle of neutral layer deviation, bending moment, wall thickness variation and crosssection distortion, are developed to explain the phenomena in tube bending and their magnitudes are also determined. During unloading process, the springback angle is deduced using the virtual work principle, and springback radius is also given according to the length of the neutral layer which remains unchanged before and after springback. The theoretical formulae are validated by the experimental results or the validated simulation results in literature, which can be used to auicklv predict the forming aualitv of tube numerical control （NC） bending.
基金funded by the National Science and technology Major Project(2008ZX05001)
文摘The exploration targets in the Kuqa Depression at present are mainly structure traps in Cretaceous-Tertiary.Due to the complexity of mountain distribution and reservoir forming conditions, the exploration of Jurassic in the eastern Kuqa Depression has been in a state of semi-stagnation since the discovery of the Yinan-2 gas reservoir.According to the concept and theory of 'continuous petroleum reservoirs' and the re-analysis of the forming conditions of the Yinan-2 gas reservoir and regional natural gas in the eastern Kuqa Depression,it is believed that the deep Jurassic has good natural gas accumulation conditions as well as geological conditions for forming continuous tight gas reservoirs.The boundary of the Yinan-2 gas reservoir is not controlled by a structural spillpoint.The downdip part of the structure is dominated by gas,while the hanging wall of the fault is filled by water and forming obvious inverted gas and water.The gas reservoir has the normal temperature and ultrahigh pressure which formed in the near source or inner-source.All of these characteristics indicate that the Yinan-2 gas reservoir is different from conventional gas reservoirs.The deep Jurassic in the eastern Kuqa Depression has multisets of source-reservoir-cap assemblages,which comprise interbedded sandstones and mudstones.These assemblages are characterized by a self-generation,self-preserving and self-coverage model.Reservoir sandstones and coal measure mudstones are interbedded with each other at a large scale.As the source rocks,Triassic-Jurassic coal measure mudstones distribute continuously at a large scale and can generate and expel hydrocarbon.Source rocks contact intimately with the overlying sandstone reservoirs.During the late stage of hydrocarbon expulsion,natural gas charged continuously and directly into the neighboring reservoirs.Petroleum migrated mainly in a vertical direction over short distances.With ultra-high pressure and strong charging intensity,natural gas accumulated continuously.Reservoirs are dominated by sandstones of braided delta facies.The sand bodies distribute continuously horizontal.With low porosity and low permeability,the reservoirs are featured by strong heterogeneity.It is hypothesized that the sandstones of the interior depression tend to be relatively tight with increasing depth and structure stress weakness.Thus,it is predicted that continuous tight gas reservoirs of ultra-high pressure may exist in the deep formations of the eastern and even the whole Kuqa Depression.So,it is worth evaluating the exploration potential.
基金the National Natural Science Foundation of China(Nos.5090514451275415)National Basic Research Program of China(No.2010CB731701)+2 种基金Program for New Century Excellent Talents in University,Fundamental Research Funds for the Central Universities(3102014KYJD001)of Chinathe EU Marie Curie Actions–Mat Pro Future Project(FP7-PEOPLE-2012-IRSES-318968)of Chinathe‘‘111"Project(B08040)of China for the support to this research
文摘The precision forming of thin-walled components has been urgently needed in aviation and aerospace field. However, the wrinkling induced by the compressive instability is one of the major defects in thin-walled part forming. The initiation and growth of the wrinkles are interac- tively affected by many factors such as stress states, mechanical properties of the material, geometry of the workpiece and boundary conditions. Especially when the forming process involves compli- cated boundary conditions such as multi-dies constrains, the perturbation of clearances between workpiece and dies and the contact conditions changing in time and space, etc., the predication of the wrinkling is further complicated. In this paper, the cu.rent prediction methods were summa- rized including the static equilibrium method, the energy method, the initial imperfection method, the eigenvalue buckling analysis method, the static-implicit finite element method and the dynamic- explicit finite element method. Then, a systematical comparison and summary of these methods in terms of their advantages and limitations are presented. By using a combination of explicit FE method, initial imperfection and energy conservation, a hybrid method is recommended to predict plastic wrinkling in thin-walled part forming. Finally, considering the urgent requirements of com- plex thin-walled structures＇ part in aviation and aerospace field, the trends and challenges in wrin- kling prediction under complicated boundary conditions are presented.
