Finite element numerical simulation method for rolling forming of double-zero aluminum foil

Abstract

The invention discloses a double-zero aluminum foil rolling forming finite element numerical simulation method, which comprises the following steps of S1, obtaining material constitutive parameters of an aluminum foil by carrying out stretching and compression experiments on an aluminum foil sample at different strain rates, importing the obtained material constitutive parameters of the aluminum foil into ABAQUS software based on a nonlinear finite element software ABAQUS platform, and carrying out numerical simulation on the obtained material constitutive parameters of the aluminum foil; establishing a numerical prediction model for rolling forming of the double-zero aluminum foil; s2, based on the numerical prediction model of double-zero aluminum foil rolling forming, the equivalent plastic deformation of each pass of double-zero aluminum foil rolling, the flow condition of metal in the rolling process, the stress-strain distribution rule of each pass and the magnitude of residual stress in each stage are analyzed, and aluminum foil deformation characteristics and a deformation mechanism in the whole double-zero aluminum foil rolling forming process are revealed; and S3, based on the numerical prediction model for double-zero aluminum foil rolling forming, the influence of technological parameters such as the rolling speed, the lubricating condition, the front-back tension and the roller roughness on the aluminum foil forming quality is analyzed.

Description

Technical Field

[0001] The present invention relates to the technical field of double-zero aluminum foil rolling forming, and particularly to a finite element numerical simulation method for double-zero aluminum foil rolling forming. Background Art

[0002] The cold rolling process of double-zero aluminum foil is a multi-pass, unsteady, non-linear and multi-factor complex physical process; the roll roughness, rolling oil lubrication conditions, rolling speed, front and rear tensions, etc. are crucial for the forming quality of aluminum foil. If finite element numerical simulation technology (such as software like ABAQUS, ANSYS, DEFORM, etc.) is used for simulation analysis, process parameters can be optimized, defects can be predicted, and experimental costs can be reduced. Summary of the Invention

[0003] In view of the above technical problems, the present invention provides a finite element numerical simulation method for double-zero aluminum foil rolling forming.

[0004] In order to achieve the above object, the technical solution of the present invention is as follows: A finite element numerical simulation method for double-zero aluminum foil rolling forming, comprising the following steps: S1. Through tensile and compression experiments on aluminum foil specimens at different strain rates, obtain the material constitutive parameters of the aluminum foil. Based on the non-linear finite element software ABAQUS platform, import the obtained aluminum foil material constitutive parameters into the ABAQUS software to establish a numerical prediction model for double-zero aluminum foil rolling forming; S2. Based on the numerical prediction model for double-zero aluminum foil rolling forming, analyze the equivalent plastic deformation of each pass of double-zero aluminum foil rolling, the metal flow situation during the rolling process, the stress-strain distribution law of each pass, and the magnitude of residual stress at each stage, and reveal the deformation characteristics and deformation mechanism of the aluminum foil during the whole process of double-zero aluminum foil rolling forming; S3. Based on the numerical prediction model for double-zero aluminum foil rolling forming, analyze the influence of process parameters such as rolling speed, lubrication conditions, front and rear tensions, and roll roughness on the forming quality of aluminum foil.

[0005] The beneficial effects of the present invention are: 1. Optimize process parameters (such as reduction rate, tension, rolling speed) through finite element numerical simulation, reduce trial-and-error costs, and shorten the new product R & D cycle. Before aluminum foil rolling, the rolling force can be predicted by FEA to avoid equipment overload or product defects caused by improper parameters.

[0006] 2. Identify potential defects in advance (such as edge wrinkling, uneven thickness, surface scratches), guide process improvement, and reduce the scrap rate.

[0007] 3. Quickly evaluate the influence of different parameters (friction coefficient, material hardening model, roll radius) on the results and determine the key control variables. Detailed Embodiment

[0008] To make the objectives, technical solutions, and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below in conjunction with specific embodiments. It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the present invention. In addition, in the following description, the descriptions of well-known structures and technologies are omitted to avoid unnecessarily confusing the concepts of the present invention.

[0009] A finite element numerical simulation method for the forming of double-zero aluminum foil includes the following steps: S1. Through tensile and compression experiments on aluminum foil specimens at different strain rates, obtain the material constitutive parameters of the aluminum foil. Based on the nonlinear finite element software ABAQUS platform, import the obtained material constitutive parameters of the aluminum foil into the ABAQUS software to establish a numerical prediction model for the forming of double-zero aluminum foil; S2. Based on the numerical prediction model for the forming of double-zero aluminum foil, analyze the equivalent plastic deformation in each pass of double-zero aluminum foil rolling, the metal flow during the rolling process, the stress-strain distribution law in each pass, and the magnitude of residual stress in each stage, and reveal the deformation characteristics and deformation mechanism of the aluminum foil during the whole process of double-zero aluminum foil rolling forming; S3. Based on the numerical prediction model for the forming of double-zero aluminum foil, analyze the influence of process parameters such as rolling speed, lubrication conditions, front and back tensions, and roll roughness on the forming quality of the aluminum foil.

[0010] Specifically, the establishment of the finite element numerical model for the forming of zero aluminum foil includes the construction of the die, the acquisition and setting of material constitutive parameters, the assembly relationship between the dies, the division of the element mesh, the interaction relationship between the model components, and the setting of the boundary load conditions for each component, etc.

[0011] 1. Construct a rolling mill model through the nonlinear finite element software ABAQUS / CAE. To simplify the model and reduce the influence of uncertain factors, the rolling mill can be directly simplified into upper and lower backup rolls, upper and lower work rolls, and aluminum foil; 2. Define the material properties. The basic parameters of the material properties in the ABAQUS software include material density, Poisson's ratio, Young's modulus, true stress-strain curve parameters, etc. In the actual rolling production process, since the material strength and hardness of the roll are much higher than that of the aluminum foil, almost no macroscopic deformation occurs during the aluminum foil rolling process. Therefore, to save the calculation cost and reduce the influence of uncertain factors, the roll can be directly set as a rigid body. The aluminum foil rolling process will not only undergo compressive deformation but also tensile deformation. Therefore, tensile and compression experiments need to be carried out on the aluminum foil specimen, and all the material constitutive parameters of the aluminum foil are imported into the ABAQUS software to establish the material constitutive parameters of the aluminum foil, and the material constitutive parameters of the aluminum foil are assigned to the aluminum foil die.

[0012] 3. Mesh generation: As the basis of finite element numerical simulation analysis, the size and type of the model mesh are important factors affecting the calculation results. Since the upper and lower backup rolls and the work rolls do not participate in deformation during the entire rolling process, a four-node three-dimensional quadrilateral rigid element R3D4 is used for discretization. During the rolling process, the aluminum foil will undergo large deformations. To prevent the hourglass phenomenon caused by deformation, the aluminum foil needs to be divided into finer meshes, and an eight-node hexahedron reduced integration solid element C3D8R is used for discretization.

[0013] 4. Definition of contact friction: During the deformation process, there is rolling contact between the upper and lower roll holes and the backup rolls, and there is rolling contact and sliding contact between the surface of the aluminum foil and the work roll. The sliding contact is set as a tangential attribute to define the friction coefficient; the rolling contact is set as a normal attribute to define normal contact attributes such as contact stiffness.

[0014] 5. Setting of load boundary conditions: Set the boundary conditions of the model according to the actual situation, give the initial velocity of the aluminum foil at the entrance. After the aluminum foil completely passes through the roll system, set the velocity of the aluminum foil perpendicular to the rolling direction to zero, and set the front tension and rear tension in the rolling direction.

[0015] Evaluation of the reliability of the finite element model: When the ratio of the artificial strain energy (ALLAE) to the internal energy (ALLIE) does not exceed 5%-10% during most of the calculation process of the finite element model, and the kinetic energy (ALLKE) changes stably, it proves the reliability of the aluminum foil rolling model.

[0016] It should be understood that the above specific embodiments of the present invention are only used for exemplary illustration or explanation of the principle of the present invention, and do not constitute a limitation to the present invention. Therefore, any modifications, equivalent replacements, improvements, etc. made without departing from the spirit and scope of the present invention shall be included within the protection scope of the present invention. In addition, the appended claims of the present invention are intended to cover all variations and modifications that fall within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. A finite element numerical simulation method for the rolling forming of double-zero aluminum foil, characterized in that The steps include the following: S1. Through tensile and compression experiments on aluminum foil specimens at different strain rates, obtain the material constitutive parameters of the aluminum foil. Based on the nonlinear finite element software ABAQUS platform, import the obtained aluminum foil material constitutive parameters into the ABAQUS software to establish a numerical prediction model for the rolling forming of double-zero aluminum foil; S2. Based on the numerical prediction model for the rolling forming of double-zero aluminum foil, analyze the equivalent plastic deformation in each pass of double-zero aluminum foil rolling, the metal flow during the rolling process, the stress-strain distribution law in each pass, and the magnitude of residual stress in each stage, and reveal the deformation characteristics and deformation mechanism of aluminum foil during the whole process of double-zero aluminum foil rolling forming; S3. Based on the numerical prediction model for the rolling forming of double-zero aluminum foil, analyze the influence of process parameters such as rolling speed, lubrication conditions, front and back tensions, and roll roughness on the forming quality of aluminum foil.