Method for controlling over-bending deformation in cold-bending rolling process of aluminum alloy thin-wall corrugated groove profile

Abstract

The invention belongs to the field of metal manufacturing, and discloses a control method for over-bending deformation in the cold bending and rolling process of an aluminum alloy thin-wall corrugated groove profile, which comprises the following steps of: carrying out numerical simulation on the cold bending and rolling forming process of a multi-corrugated groove profile according to a constructed three-dimensional assembly model; and the bending plastic strain of the thin-wall profile under different cold-bending rolling forming process parameters is obtained through prediction. The influence degree of each process parameter on bending deformation is evaluated by researching the relationship between the roller diameter, the corner radius and the roller station spacing parameter and the bending plastic strain in the rolling forming process of the corrugated groove profile, so that the over-bending deformation control in the rolling process of the aluminum alloy thin-wall corrugated groove profile is achieved. According to the method, the plastic bending peak strain of the profile in the rolling process is reduced to the minimum in the mode of optimizing technological parameters, the method is also suitable for controlling over-bending deformation of multi-groove rolling forming pieces made of other alloy materials, the rolling forming quality of the profile plate is improved to a great extent, and the debugging cost of a rolling forming unit is greatly reduced.

Description

Technical Field

[0001] The invention relates to the field of metal manufacturing, and in particular to a method for controlling over-bending deformation during cold-bending rolling of an aluminum alloy thin-wall corrugated groove profile. Background Art

[0002] At present, the traditional manufacturing materials of aluminum coil support sleeves for industrial products mainly rely on paper materials. However, as the country's requirements for environmental protection control indicators become increasingly higher, the production cost of paper materials and the environmental cost during use have increased significantly. Therefore, it is of great practical value to study a new material product that is low-cost, environmentally friendly and pollution-free and can replace paper sleeves. Compared with traditional paper sleeves, industrial aluminum sleeves have the advantages of low cost, high load-bearing capacity, not easy to collapse, environmentally friendly and pollution-free, and easy to transport and manage. They have good application prospects in industry, and compared with other metal materials, they are also easy to spin-form.

[0003] As the basic material for the preparation of aluminum sleeves, aluminum alloy thin-walled corrugated groove plates face challenges during the roll forming process, especially in the bending area of ​​the groove plate, which is prone to defects such as fracture due to excessive bending and deformation. At present, the forming of multi-groove corrugated plates on the market mostly adopts stamping or hydraulic forming processes, and the roll forming process has higher production efficiency than the other two processes, and the products produced have better precision and finish, which can meet the needs of large-scale and efficient modern production. However, the roll forming mold is more complex than the stamping forming mold, and its dimensional accuracy requirements are higher. Therefore, determining the appropriate mold size and forming parameters can better control the tearing of the groove plate caused by excessive bending and deformation of the plate during the rolling process. Summary of the invention

[0004] The purpose of the present invention is to provide control over the over-bending deformation of aluminum alloy thin-walled corrugated groove profiles during cold bending and rolling, so as to solve the problem of local tearing of aluminum alloy thin-walled corrugated grooves caused by excessive bending. The problem of tearing easily occurring during roll forming of other alloy multi-groove profiles can also be used as a reference.

[0005] The technical solution of the present invention is as follows:

[0006] A method for controlling bending deformation during cold bending and rolling of aluminum alloy thin-wall corrugated groove profiles, which is characterized by comprising the following steps:

[0007] S1. According to the forming geometry of aluminum alloy thin-wall corrugated groove profiles, a roller pattern of multi-groove profiles formed in each pass is constructed, and the surface dimensions of the rollers in each pass are determined;

[0008] S2. Construct a three-dimensional assembly model of the forming die that is consistent with the actual production environment;

[0009] S3. Based on the three-dimensional assembly model, the roll forming and springback process of the aluminum alloy sheet were numerically simulated using finite element simulation software to analyze the bending plastic strain of the corrugated groove profile under different cold bending roll forming process parameters;

[0010] S4. Analyze the influence of different process parameters on the bending deformation of the corrugated fluted plate, including the influence of the roller diameter, the bending radius and the roller station spacing;

[0011] S5. According to the influence relationship determined in step S4, the process parameters are optimized to control the bending deformation of the aluminum alloy thin-walled corrugated groove profile so as to minimize the plastic bending peak strain.

[0012] Furthermore, in the simulation analysis of step S3, the upper and lower rollers are regarded as rigid bodies, the lower roller is used as a driving roller, and is driven by a motor to rotate clockwise. The rotation of the upper roller is driven by the friction between the roller and the plate, and the feed speed of the plate is consistent with the actual production feed speed.

[0013] Furthermore, the influence of the optimized process parameters on the peak plastic strain of the corrugated fluted profile is disclosed, wherein the peak plastic strain of the bending is used to represent the bending deformation of the corrugated fluted plate, and the larger the value, the greater the risk of tearing in the bending area.

[0014] Furthermore, by adjusting the process parameters of the roller diameter, the bending radius and the roller station spacing, the bending deformation during the rolling process of the thin-walled aluminum alloy corrugated groove profile is controlled to solve the problem of local tearing caused by excessive bending.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] Through numerical simulation, the bending plastic strain of the profile under various rolling process parameters is predicted, and the influence relationship between the local bending deformation of the groove plate and various parameters is analyzed to control the excessive bending deformation of the groove plate during rolling, thereby avoiding the tearing defects that are easy to occur in the forming process of multi-groove profiles. At the same time, this method greatly reduces the commissioning cost of the roll forming unit and improves the product quality of the aluminum alloy groove plate. This method is also applicable to the control of excessive bending deformation of other alloy multi-groove profiles during rolling. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 The present invention is a flow chart of a method for controlling bending deformation during cold bending and rolling of aluminum alloy thin-walled corrugated groove profiles.

[0018] Figure 2 It is the matching roller for each pass in the corrugated groove profile forming process of the present invention (only one pass is shown).

[0019] Figure 3 This is the geometric model of the three-dimensional assembly of the present invention (only three passes are shown).

[0020] Figure 4 The sampling points are in the bending area of ​​aluminum alloy thin-walled corrugated plate. DETAILED DESCRIPTION

[0021] In order to achieve the above-mentioned purpose, the technical solution of the present invention is further described below in conjunction with the accompanying drawings and embodiments, but the protection scope of the present invention should not be limited thereto.

[0022] See also Figure 1 , Figure 1 This is a flow chart of a method for controlling bending deformation during cold bending and rolling of an aluminum alloy thin-walled corrugated groove profile according to the present invention. As shown in the figure, a method for controlling bending deformation during cold bending and rolling of an aluminum alloy thin-walled corrugated groove profile according to this embodiment includes the following steps:

[0023] S1. According to the final forming geometry of aluminum alloy thin-wall corrugated groove profiles, a roller pattern that can guide actual production is produced, and the profile cross section in each pass can be accurately designed with rollers:

[0024] According to the final geometric dimensions of the aluminum alloy thin-wall corrugated groove profile, the roller pattern of the multi-groove profile in each pass is constructed based on the COPRA software, and then the profile section in each pass is matched with rollers. Figure 2 In the cold bending roll forming process of metal sheets, the roll pattern is an important drawing used to guide the design and manufacture of the rolls. It details the surface shape and size of the rolls at each pass to ensure that the sheet can be deformed according to the predetermined shape and size when passing through the rolls. According to the roll pattern, the appropriate roll is selected for each pass, including the roll diameter, surface shape (such as the shape and depth of the corrugated groove), and the relative position between the rolls. The accuracy of the roll matching is crucial to ensure the quality and shape of the final product.

[0025] S2. Construct a three-dimensional assembly model of the forming die that is highly consistent with the actual production environment to facilitate subsequent numerical simulation and simulation analysis:

[0026] The 3D assembly model of the forming mold is constructed based on Solidworks 2016 modeling software.

[0027] According to the forming mold in actual production, a three-dimensional model forming mold of an upper roller (convex mold) 1, a lower roller (concave mold) 2 and a thin-walled plate 3 placed therebetween is constructed.

[0028] Ensure that the design assembly is consistent with the actual production, including key parameters such as roller diameter, roller station spacing, and bend radius. In the model, 13 passes are used to complete the entire forming process of the aluminum alloy sheet, such as Figure 3 shown.

[0029] S3. The cold bending roll forming and springback process of aluminum alloy thin-wall corrugated groove profiles were numerically simulated using finite element simulation software to predict and evaluate the forming effects under different process parameters:

[0030] Import the constructed 3D assembly model into the simulation software in x_t file format.

[0031] Set material properties in the software, such as elastic modulus and yield strength of 6061-T6 aluminum alloy.

[0032] Set boundary conditions and loads, such as the rotation mode of the upper and lower rollers, the feed speed of the plate, etc. Among them, the upper and lower rollers are regarded as rigid bodies, the lower roller is driven by the motor as the driving roller to rotate clockwise, and the rotation of the upper roller is driven by the friction between the roller and the plate.

[0033] The forming process of the sheet metal is simulated using dynamic solution technology to ensure that the feed speed of the sheet metal is consistent with the feed speed in actual production.

[0034] Through simulation analysis, key data such as the forming effect and bending peak plastic strain of the sheet under different process parameters are obtained.

[0035] S4. Analyze the influence of different process parameters on the bending deformation of the corrugated fluted plate to find the optimal combination of process parameters.

[0036] In this embodiment, the width of the plate is 110 mm, the thickness is 0.25 mm, the material used is 6061-T6 aluminum alloy, and other rolling process parameters are shown in Table 1 below. The bending peak plastic strain is used to represent the bending deformation of the corrugated fluted plate. The larger the value, the greater the risk of tearing in the bending area. The sampling point of the fluted plate bending area is unit 4142, see Figure 4 , used to extract and analyze the bending peak plastic strain data. Based on the data in Table 1, the influence relationship between each process parameter and the bending peak plastic strain at the sampling point is analyzed.

[0037] Table 1

[0038]

[0039] S5 interprets the simulation analysis results and evaluates the impact of different process parameters on the risk of tearing of corrugated fluted plates:

[0040] The analysis results show that the roller diameter is proportional to the bending peak strain. Only when the roller diameter is small, the change of this parameter has a certain influence on the tearing defect of the product, but the influence is weak. When the roller diameter increases to a certain extent, the influence on the defect can be ignored. Increasing the roller station spacing Although the roller station spacing can reduce the tearing risk of asymmetric corrugated groove plates, it has no effect on it when it increases to a certain extent. At the same time, expanding the roller station spacing means lengthening the product production line, resulting in a waste of experimental space and increased costs. Reducing the bending radius significantly increases the bending peak strain at the corner of the groove plate, exacerbating the risk of tearing of the groove plate.

[0041] S6. According to the simulation analysis results, the process parameters are adjusted and experimental research is carried out to verify the control effect of the adjusted parameters on the bending deformation of thin-walled aluminum alloy corrugated groove profiles during rolling process:

[0042] According to the simulation analysis results and interpretation, adjust the process parameters to the optimal combination.

[0043] The adjusted process parameters were used to carry out experimental research, and key data such as forming effect and bending peak plastic strain were observed and recorded.

[0044] Compare the test data with the simulation analysis results to verify whether the control effect of the adjusted parameters on cornering deformation meets the expectations.

[0045] Further parameter fine-tuning and optimization are carried out based on the test results to ensure that the final process parameter combination can meet production requirements and reduce the risk of tearing.

Claims

1. A method for controlling bending deformation during cold bending and rolling of aluminum alloy thin-walled corrugated groove profiles, characterized in that: The following steps are involved: S1. According to the forming geometry of aluminum alloy thin-wall corrugated groove profiles, a roller pattern of multi-groove profiles formed in each pass is constructed, and the surface dimensions of the rollers in each pass are determined; S2. Construct a three-dimensional assembly model of the forming die that is consistent with the actual production environment; S3. Based on the three-dimensional assembly model, the roll forming and springback process of the aluminum alloy sheet were numerically simulated using finite element simulation software to analyze the bending plastic strain of the corrugated groove profile under different cold bending roll forming process parameters; S4. Analyze the influence of different process parameters on the bending deformation of the corrugated fluted plate, including the influence of the roller diameter, the bending radius and the roller station spacing; S5. According to the influence relationship determined in step S4, the process parameters are optimized to control the bending deformation of the aluminum alloy thin-walled corrugated groove profile so as to minimize the plastic bending peak strain.

2. The method for controlling bending deformation during cold bending and rolling of aluminum alloy thin-walled corrugated groove profiles according to claim 1 is characterized in that: In the simulation analysis of step S3, the upper and lower rollers are regarded as rigid bodies, the lower roller is used as a driving roller, and is driven by a motor to rotate clockwise. The rotation of the upper roller is driven by the friction between the roller and the plate, and the feed speed of the plate is consistent with the actual production feed speed.

3. The method for controlling bending deformation during cold bending and rolling of aluminum alloy thin-walled corrugated groove profiles according to claim 1 is characterized in that: The influence relationship of the optimized process parameters on the bending peak plastic strain of the corrugated fluted profile, wherein the bending peak plastic strain is used to represent the bending deformation of the corrugated fluted plate. The larger the value, the greater the risk of tearing in the bending area.

4. The method for controlling bending deformation during cold bending and rolling of aluminum alloy thin-walled corrugated groove profiles according to any one of claims 1 to 3, characterized in that: By adjusting the process parameters of roller diameter, bending radius and roller station spacing, the bending deformation of thin-walled aluminum alloy corrugated groove profiles during rolling is controlled to solve the problem of local tearing caused by excessive bending.

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