Numerical simulation method and system for composite metal forming based on layering principle

Abstract

The invention discloses a numerical simulation method and system for composite metal forming based on the layering principle, and relates to the technical field of numerical simulation analysis. Finite element software Solidworks is adopted to construct a blank shape, and a corresponding mold shape is constructed; layering principle assembling operation is conducted on the multiple built blank shapes and mold shapes, and an STL model is generated; the STL model is imported into finite element software Deform, and grid division is carried out; constant shear friction is adopted between the blank and the mold, and a friction value is set; and setting process parameters of the mold, generating a data file, and carrying out simulation analysis. Simulation of the multi-blank forming process is met through layering principle simulation setting, and the deformation process of each blank in the forming process is accurately analyzed.

Description

Technical Field

[0001] The present invention relates to the technical field of numerical simulation analysis, and more specifically, to a numerical simulation method and system for composite metal forming based on the layering principle. Background Art

[0002] In recent years, the composite metal deoxidizer produced by the metallurgical method in industry is facing an urgent transformation problem. The plastic deformation method for producing composite metal is currently the most popular and feasible production and processing method. However, according to the on-site processing results, the composite metal produced by the plastic deformation method has disadvantages such as being easy to break and is not easy to form during the forming process. Therefore, exploring the forming process of composite metal produced by the plastic deformation method is a current technical problem.

[0003] Among them, for the process of producing composite metal by the plastic deformation method, the size and reasonable assembly of the blank inside the mold are the keys to realizing the forming process and obtaining high-quality composite metal products. Especially when the number of blanks is too large and the sizes are complex, it is difficult to observe the specific deformation situation of the forming process relying on experimental rules, which easily leads to adverse defects such as holes, resulting in a reduction in the mechanical properties of the composite metal.

[0004] At present, when performing finite element numerical simulation on the forming process of composite metal, especially for the forming process of multiple numbers and multiple types of blanks, there is less research. Therefore, the finite element numerical simulation method cannot be used to obtain the numerical simulation and simulation of the forming process of composite metal produced by the plastic deformation method, resulting in a large difference between the simulation result and the actual result, which seriously affects the production period, product quality, and increases production costs. The key reason is that there is a lack of necessary theoretical support for the production of composite metal by the plastic deformation method, thus restricting the industrial application of this production method.

[0005] Therefore, how to provide a numerical simulation method and system for composite metal forming based on the layering principle, and simulate and set through the "layering principle" to meet the simulation of the multi-blank forming process and accurately analyze the deformation process of each blank during the forming process is an urgent problem to be solved by those skilled in the art. Summary of the Invention

[0006] In view of this, the present invention provides a numerical simulation method and system for composite metal forming based on the layering principle, which solves the problem that in the process of finite element simulation of composite metal forming, due to the existing numerical simulation methods being unable to accurately obtain the forming process of multiple numbers and multiple types of blanks. Therefore, the present invention provides a numerical simulation method for composite metal forming prepared from the above-mentioned blanks, and simulates and sets through the "layering principle" to meet the simulation of the multi-blank forming process, and can accurately analyze the deformation process of each blank during the forming process.

[0007] To achieve the above object, the present invention adopts the following technical solutions: A numerical simulation method for composite metal forming based on the layering principle, comprising:

[0008] Using the finite element software Solidworks to construct the blank shape and construct the corresponding die shape;

[0009] Performing layering principle assembly operations on the constructed multiple blank shapes and die shapes to generate an STL model;

[0010] Importing the STL model into the finite element software Deform for mesh generation;

[0011] Adopting constant shear friction between the blank and the die and setting the friction value;

[0012] Setting the process parameters of the die, generating a data file, and performing simulation analysis.

[0013] Preferably, there are two or more blank shapes.

[0014] Preferably, tetrahedral mesh elements are used for mesh generation.

[0015] Preferably, the simulation step size is set according to the minimum mesh size; the calculation step size in finite element simulation is 1 / 3 of the minimum mesh.

[0016] Preferably, the material parameters of the blank are set as metals (non-ferrous metals, ferrous metals, rare metals, inorganic non-metallic materials, etc.) and metal compounds.

[0017] Preferably, the process parameters of the die include: the heat transfer coefficient between the die and the blank, the ambient temperature, the movement direction and movement speed of the die.

[0018] Preferably, a numerical simulation system for composite metal forming based on the layering principle, comprising:

[0019] A blank and die construction module for using the finite element software Solidworks to construct the blank shape and construct the corresponding die shape;

[0020] An STL model generation module for performing layering principle assembly operations on the constructed multiple blank shapes and die shapes to generate an STL model;

[0021] A mesh generation module for importing the STL model into the finite element software Deform for mesh generation;

[0022] A shear friction module for adopting constant shear friction between the blank and the die and setting the friction value;

[0023] A simulation analysis module is used to set the process parameters of the mold, generate data files, and conduct simulation analysis.

[0024] As can be seen from the above technical solutions, compared with the prior art, the present invention discloses a numerical simulation method and system for composite metal forming based on the layering principle, including: using the finite element software Solidworks to construct the blank shape and construct the corresponding mold shape; performing layering principle assembly operations on the constructed multiple blank shapes and mold shapes to generate an STL model; importing the STL model into the finite element software Deform for mesh generation; adopting constant shear friction between the blank and the mold and setting the friction value; setting the process parameters of the mold, generating data files, and conducting simulation analysis. The main advantages of the present invention are as follows: ① Compared with the existing simulation methods, the present invention provides a numerical simulation setting based on the "layering principle", which can realize the numerical simulation process of multiple blank forming. ② The present invention can realize the forming process of two or more kinds of metal and metal compound blanks, and can simultaneously simulate blanks of various shapes. ③ The present invention can conduct numerical simulation on metal and metal compound blanks with two different deformation resistances, and the simulation results show that metals with different deformation resistances have different deformation laws during the deformation process. ③ The present invention can change the mold shape to achieve diversification of the finished product shape. ④ Based on the Deform simulation software, the present invention can realize numerical simulation experiments of various processing methods. ⑤ The present invention can accurately simulate and simulate the composite metal forming process, clarify the characteristics of metal flow, and is suitable for solving practical engineering problems. Description of the Drawings

[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only the embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained according to the provided drawings without creative efforts.

[0026] Figure 1 It is a schematic flowchart of a numerical simulation method for composite metal forming based on the layering principle provided by an embodiment of the present invention.

[0027] Figure 2 It is a schematic diagram of a granular blank model provided by Embodiment 1 of the present invention;

[0028] Figure 3 It is a schematic diagram of a mold model provided by Embodiment 1 of the present invention;

[0029] Figure 4 It is an assembly drawing of the model provided by Embodiment 1 of the present invention;

[0030] Figure 5Schematic diagram of the finite element mesh division of the model provided in Embodiment 1 of the present invention;

[0031] Figure 6 Schematic diagram of the metal flow behavior obtained by finite element method calculation provided in Embodiment 1 of the present invention;

[0032] Figure 7 Schematic diagram of the chip-shaped blank model provided in Embodiment 2 of the present invention;

[0033] Figure 8 Schematic diagram of the die model provided in Embodiment 2 of the present invention;

[0034] Figure 9 Assembly drawing of the model provided in Embodiment 2 of the present invention;

[0035] Figure 10 Schematic diagram of the finite element mesh division of the model provided in Embodiment 2 of the present invention;

[0036] Figure 11 Schematic diagram of the metal flow behavior obtained by finite element method calculation provided in Embodiment 2 of the present invention;

[0037] Figure 12 Schematic diagram of the chip-shaped blank model provided in Embodiment 3 of the present invention;

[0038] Figure 13 Schematic diagram of the die model provided in Embodiment 3 of the present invention

[0039] Figure 14 Assembly drawing of the model provided in Embodiment 3 of the present invention;

[0040] Figure 15 Schematic diagram of the finite element mesh division of the model provided in Embodiment 3 of the present invention;

[0041] Figure 16 Schematic diagram of the metal flow behavior obtained by finite element method calculation provided in Embodiment 3 of the present invention. Detailed implementation manners

[0042] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0043] The embodiments of the present invention disclose a numerical simulation method for composite metal forming based on the layering principle, as Figure 1 shown, including:

[0044] Use the finite element software Solidworks to construct the blank shape and the corresponding die shape;

[0045] In the embodiment of the present invention, the finite element software Deform-3D is used to simulate the metal forming process. First, the geometric model is processed. First, determine the shape, size and quantity of the blank, and use the software Solidworks to construct the blank; then determine the shape of the die, and use the software Solidworks to construct the upper die and the lower die;

[0046] Perform the layering principle assembly operation on the constructed multiple blank shapes and die shapes to generate an STL model; in the Solidworks software, perform the "layering method" assembly on the constructed blank, upper die and lower die, and then save them as STL models respectively;

[0047] Import the STL model into the finite element software Deform for mesh generation; import the STL model into the finite element software Deform, and set the specific material parameters of the blank; use tetrahedral mesh elements for absolute mesh generation, and the number of meshes for each blank is 8000-20000, and the specific value is adjusted according to the blank size;

[0048] A constant shear friction is adopted between the blank and the die, and the friction value is set, and the friction value is set to 0.12;

[0049] Set the process parameters of the die to generate a data file for simulation analysis. In the finite element software Deform-3D, apply the specific processing process parameters. The calculation step length during finite element simulation should be 1 / 3 of the minimum mesh, generate a data file, and perform simulation analysis.

[0050] Specifically, there are two or more blank shapes. Set the number of blanks to two or more blanks, and set the "shape of the blank" to shapes such as circular, elliptical, rectangular, round bar, etc. After being pressed by different dies, the "finished product shape" is formed. Set the shape of the die, that is, set the "finished product shape" to shapes such as circular, elliptical, rectangular, round bar, etc.

[0051] Specifically, tetrahedral mesh elements are used for mesh generation.

[0052] Specifically, set the assembly method of multiple blanks as the "layering principle", and the "cross stacking method" can be specifically adopted.

[0053] Specifically, the process of the cross stacking method includes: place the blanks of the same material on the same layer according to the "shape of the blank", and then place the next layer after completion. The thickness dimension of this "placement layer" is determined by itself according to needs;

[0054] When the dimensions of the blank (length, width, and height) exhibit the characteristic of "asymmetry", it is placed at a certain angle along the long axis direction, and the included angle must be greater than 0°.

[0055] Specifically, the simulation step size is set according to the minimum mesh size; the calculation step size in finite element simulation is 1 / 3 of the minimum mesh.

[0056] Specifically, the material parameters of the blank are set as metals (non-ferrous metals, ferrous metals, rare metals, inorganic non-metallic materials, etc.) and metal compounds.

[0057] Specifically, the numerical simulation processing methods can be set as rolling, forging, extrusion, etc.

[0058] Specifically, the process parameters of the mold include: the heat transfer coefficient between the mold and the blank, the ambient temperature, the moving direction and moving speed of the mold.

[0059] The purpose of the embodiments of the present invention is to solve the problem that in the finite element simulation process of composite metal forming, since the existing numerical simulation methods cannot accurately obtain the forming process of multiple quantities and multiple types of blanks, so the embodiments of the present invention provide a composite metal forming numerical simulation method prepared from the above-mentioned blanks. By simulating and setting according to the "layering principle" to meet the simulation and simulation of the multi-blank forming process, the deformation process of each blank in the forming process can be accurately analyzed.

[0060] To solve the above technical problems, according to different applications, the types of blanks involved in the embodiments of the present invention are metals (non-ferrous metals, ferrous metals, rare metals, inorganic non-metallic materials, etc.) and metal compounds. The shapes of the blanks, molds, and finished products involved are circular, elliptical, rectangular, round bar-shaped, etc. The processing methods involved are forging, extrusion, rolling, etc. When performing numerical simulation, the types of blanks, shapes, mold shapes, and processing methods can be selected by oneself to achieve the accuracy of finite element numerical simulation. The size range of the granular blanks involved: the diameter is 5 - 150 mm, the size range of the chip-shaped blanks involved is: the diameter is 5 - 150 mm, and the thickness is 1 - 15 mm. The deformation temperature is 25 - 150 °C.

[0061] The embodiments of the present invention are applicable to the forming process of two or more metals (non-ferrous metals, ferrous metals, rare metals, inorganic non-metals, etc.) and metal compounds, and use the "layering principle" for simulation, especially for the numerical simulation of multiple quantities and multiple types of blanks. The simulation results are in good agreement with the actual processing results, which can not only improve the numerical simulation accuracy, but also significantly improve the multi-blank composite plastic forming efficiency and product quality.

[0062] In a specific embodiment of the present invention, a numerical simulation system for composite metal forming based on the layering principle includes:

[0063] Blank and die building modules are used to build the blank shape and the corresponding die shape using the finite element software Solidworks;

[0064] STL model generation module is used to perform hierarchical principle assembly operations on the constructed multiple blank shapes and die shapes to generate an STL model;

[0065] Mesh generation module is used to import the STL model into the finite element software Deform for mesh generation;

[0066] Shear friction module is used to adopt constant shear friction between the blank and the die and set the friction value;

[0067] Simulation analysis module is used to set the process parameters of the die, generate a data file, and perform simulation analysis.

[0068] Example 1

[0069] Example 1 of the present invention is the simulation process of granular composite metal. The blank material is 6061Al alloy and 1045 steel. The blank diameter is 10 mm. The simulation temperature is set at 25 °C, and the extrusion forming process is selected for simulation. The specific shape of the granular blank is as Figure 2 shown in (a) and (b). To simplify the simulation process, a 1 / 4 cylindrical die is selected for this numerical simulation experiment. The specific dimensions and shape of the die are as Figure 3 shown in (a) and (b). The "layered principle" is used to set the blank, and the specific assembly drawing is as Figure 4 shown.

[0070] The operation steps are as follows:

[0071] ① Process the geometric model and construct the geometric solid model using the software Solidworks.

[0072] ② In the software Solidworks, assemble the constructed die and blank, and then save them as STL models respectively.

[0073] ③ Import the STL model into the finite element software Deform. Set the Al particle material as AL6061Machining-Johnson, the Fe particle material as AISI-1045, COLD[70F(20C)]. Adopt tetrahedral mesh elements and absolute mesh generation. Set the number of mesh divisions for each blank as 8000. The finite element mesh generation diagram of the blank is as Figure 5 shown. The heat transfer coefficient between the die and the blank is 5 N / s / mm / °C, and the ambient temperature is set at 25 °C.

[0074] ④ Set the movement direction of the upper die as the -Y axis and the movement speed as 0.5 mm / s.

[0075] ⑤Set the simulation step size to 0.13 according to the minimum grid size (0.39), and the total simulation step size is 10 mm.

[0076] ⑥Simulation calculation and analysis of numerical simulation results.

[0077] The metal flow velocity distribution nephograms of Al particles and Fe particles at different steps during this simulation are obtained from the above simulation operations, as Figure 6 shown.

[0078] Figure 6 In it, (a) and (b) are the metal flow velocity distribution diagrams of the upper-layer Al particles, (c) and (d) are the metal flow velocity distribution diagrams of the lower-layer Fe particles, and (e) and (f) are the metal flow velocity distribution diagrams of the upper-layer Fe particles. It can be Figure 6 seen that the Al particles on the same layer deform earlier than the Fe particles, and the direction of their metal flow velocity changes with the increase of the simulation steps. At the same time, the deformation degree of the lower-layer Fe particles is much lower than that of the upper-layer Fe particles, which proves that during the simulation deformation process, the metal billet closer to the upper die will deform first and have a greater deformation degree.

[0079] Example 2

[0080] This example is the simulation process of chip composite metal. The billet materials are 6061 Al alloy and 1045 steel. The billet diameter is 14 mm and the height is 1.5 mm. Set the simulation temperature to 25 °C and select the extrusion forming process for simulation. The specific shape of the chip billet is as Figure 7 shown in (a) and (b) in it. To simplify the simulation process, a 1 / 4 cylindrical die is selected for this numerical simulation experiment. The specific dimensions and shape of the die are as Figure 8 shown in (a) and (b) in it. The billet is set using the "layered principle", and the specific assembly drawing is as Figure 9 shown.

[0081] The operation steps are as follows:

[0082] ①Process the geometric model and construct the geometric solid model using the software Solidworks.

[0083] ②In the software Solidworks, assemble the constructed die and billet, and then save them as STL models respectively.

[0084] ③ Import the STL model into the finite element software Deform. Set the Al chip material as AL6061Machining-Johnson, the Fe chip material as AISI-1045, COLD[70F(20C)]. Use tetrahedral mesh elements and absolute mesh division. Set the number of mesh divisions for each blank as 8000. The finite element mesh division diagram of the blank is as shown in Figure 10 shown. The heat transfer coefficient between the die and the blank is 5N / s / mm / ℃, and the ambient temperature is set at 25℃.

[0085] ④ Set the moving direction of the upper die as the -Y axis and the moving speed as 0.5mm / s.

[0086] ⑤ Set the simulation step size as 0.11 according to the minimum mesh size (0.33), and the total simulation step size as 10mm.

[0087] ⑥ Conduct simulation calculation and analysis of the numerical simulation results.

[0088] The metal flow velocity distribution nephogram of Al chips at different levels and different steps during this simulation is obtained from the above simulation operations, as shown in Figure 11 shown.

[0089] From Figure 11 analysis, it can be seen that (a)-(i) respectively show that the flow velocity distributions of the Al chip blanks at different levels are different. At level A with a shorter distance from the upper die, the flow velocity at the edge gradually increases with the increase of the simulation steps. For level B and level C at a lower position, the flow velocity at the edge first decreases and then increases with the increase of the simulation steps. The reason is that the position closer to the upper die will continuously deform with the increase of the simulation steps.

[0090] Example 3

[0091] This example is the simulation process of chip-shaped composite metal. The blank material is 6061Al alloy and 1045 steel. The blank diameter is 14mm and the height is 1.5mm. Set the simulation temperature as 100℃ and select the extrusion forming process for simulation. The specific shape of the chip-shaped blank is as shown in (a) and (b) of Figure 12 . For simplifying the simulation process, select a 1 / 4 cylindrical die for this numerical simulation experiment. The specific dimensions and shape of the die are as shown in (a) and (b) of Figure 13 . Set the blank using the "layer principle", and the specific assembly diagram is as shown in Figure 14 shown.

[0092] The operation steps are as follows:

[0093] ① Process the geometric model and construct the geometric solid model using the software Solidworks.

[0094] ②In the software Solidworks, assemble the constructed mold and blank, and then save them as STL models respectively.

[0095] ③Import the STL models into the finite element software Deform. Set the Al chip material as AL6061Machining-Johnson, the Fe chip material as AISI-1045, COLD[70F(20C)], adopt tetrahedral mesh elements, absolute mesh division, and set the number of mesh divisions for each blank to 8000. The finite element mesh division diagram of the blank is as shown in Figure 15 Figure [here the figure number should be provided in the original text]. The heat transfer coefficient between the mold and the blank is 5N / s / mm / ℃, and the ambient temperature is set at 100℃.

[0096] ④Set the moving direction of the upper mold as the -Y axis and the moving speed as 0.5mm / s.

[0097] ⑤Set the simulation step size as 0.11 according to the minimum mesh size (0.33), and the total simulation step size as 10mm.

[0098] ⑥Conduct simulation calculations and analyze the numerical simulation results.

[0099] Obtain the metal flow velocity distribution nephogram of Al chips at different levels and different steps during this simulation from the above simulation operations, as shown in Figure 16 Figure [here the figure number should be provided in the original text].

[0100] From Figure 16 Analysis, it can be seen that (a)-(i) respectively show that when the simulation temperature increases, the flow velocity distribution of the Al chip blank changes significantly, and it is more obvious at the lower levels B and C. The streamline direction at the edge of the blank changes from a downward trend to a horizontal trend, indicating that the blanks at levels B and C are more likely to deform at 100℃.

[0101] In this specification, each embodiment is described in a progressive manner. The key point of each embodiment is to illustrate the differences from other embodiments. For the same or similar parts among the embodiments, reference can be made to each other. For the device disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple. For the relevant parts, reference can be made to the description in the method section.

[0102] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be obvious to those skilled in the art. The general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to these embodiments shown herein, but will conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A numerical simulation method for composite metal forming based on the layering principle, characterized in that, Including: Using the finite element software Solidworks to construct the blank shape and the corresponding die shape; Performing a hierarchical principle assembly operation on the constructed multiple blank shapes and die shapes to generate an STL model; Importing the STL model into the finite element software Deform for mesh generation; Adopting a constant shear friction between the blank and the die and setting the friction value; Setting the process parameters of the die, generating a data file, and performing a simulation analysis.

2. The numerical simulation method for composite metal forming based on the layering principle according to claim 1, characterized in that, There are two or more blank shapes.

3. A numerical simulation method for composite metal forming based on the layering principle according to claim 1, characterized in that, Adopting tetrahedral mesh elements for mesh generation.

4. A numerical simulation method for composite metal forming based on the layering principle according to claim 1, characterized in that, Setting the simulation step size according to the minimum mesh size; the calculation step size during finite element simulation is 1 / 3 of the minimum mesh.

5. A numerical simulation method for composite metal forming based on the stratification principle according to claim 4, characterized in that, Setting the material parameters of the blank as metals and metal compounds.

6. A numerical simulation method for composite metal forming based on the layering principle according to claim 1, characterized in that The process parameters of the die include: the heat transfer coefficient between the die and the blank, the ambient temperature, the movement direction and movement speed of the die.

7. A numerical simulation system for composite metal forming based on the layering principle, applying a numerical simulation method for composite metal forming based on the layering principle according to any one of claims 1-6, characterized in that Including: A blank and die construction module for using the finite element software Solidworks to construct the blank shape and the corresponding die shape; An STL model generation module for performing a hierarchical principle assembly operation on the constructed multiple blank shapes and die shapes to generate an STL model; A mesh generation module for importing the STL model into the finite element software Deform for mesh generation; A shear friction module for adopting a constant shear friction between the blank and the die and setting the friction value; A simulation analysis module for setting the process parameters of the die, generating a data file, and performing a simulation analysis.

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