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摘 要
冷弯成形是板带深加工的重要领域，是一项具有显著经济效益和社会效益的生产工艺。同时冷弯成形过程又是一个复杂的过程，通常对它的研究都是采用实验的方法。如果对其成形过程进行系统的理论和实验研究，并将这些理论和经验同现代化的数值方法和运算工具相结合，对成形过程进行计算机仿真，指导实际生产，则会具有重大理论意义和实用价值。袋形波是宽幅断面加工中经常出现的缺陷，内半径为零的弯曲也是断面设计中经常使用的。本文在国内首次对这两个问题进行有限元的计算机仿真。
本文介绍了冷弯成形工艺，查阅了有关文献，对国内外冷弯型钢的生产、应用及研究状况进行了综述，着重介绍了冷弯成形计算机仿真相关的理论的分类进展。并对冷弯成形仿真的有限元基础进行了介绍，着重介绍了有限元法的理论基础、一般求解步骤、三维问题的基本变量和基本方程、弹塑性理论、板料成形有限元基础以及相关的部分基本法则。
本文对冷弯成形过程进行了简化，根据弹塑性有限元理论及板料冷弯成形的特点，在有限元仿真软件MSC.Marc 中建立了仿真模型，并利用日本的小奈弘（Ona Hong）教授的有关宽幅断面袋形波的实验作为模型的验证依据，确定了模型的合理性。
本文利用所建立的冷弯成形过程的仿真模型对宽幅断面的袋形波进行了仿真，并利用仿真结果分析了袋形波的产生机理及其特点，验证了有关袋形波产生机理的假设。
本文利用仿真模型对我校机电工程研究所承担的韩国工业技术研究院（Korea Institute of Industrial Technology ）项目中的内半径为零弯曲部分的成形过程进行了仿真，通过对仿真结果的分析检验了轧辊设计是否能较好实现所需断面，并根据相关仿真结果对原轧辊设计提出了修改意见。文中还对内弯半径小于半个板厚时的弯曲中板料的变形特点作了数值上的分析和验证，得出了许多有价值的结论。
总之，本文所建立的冷弯成形过程的计算机仿真模型经过实验验证，证明是正确和有效的，此模型可以成功的模拟冷弯成形过程。所得结论可供研究、设计及生产冷弯型钢部门参考借鉴。
关键词： 冷弯成形 有限元法 仿真 Marc宽幅断面 零弯曲内径
ABSTRACT
Cold roll forming is an important field of sheet metal processing and new production technology with remarkable economic benefit and society benefit. On the other hand, it’s a complicate processing, the research on the processing always depends on experiments. So, it has important theoretical and practical value to carry on numerical research on cold roll forming processing with FEA software. Pocket wave is a serious defect which always can be found in wide range section. And zero inner radius is often used in section design. It’s the first time in
This paper summarizes cold roll forming technology, and the situation of internal and external production, application and research. The theoretical analysis progress on simulation of roll forming is emphasized. Besides, the paper introduces some basic knowledge on FEM, mainly about theoretical base, normal solve steps, basic variables and equations of 3D problems, elastic-plastic theory, sheet forming and some basic rules.
In this paper, the processing of cold roll forming is simplified, and the simulation model is established in MSC.Marc according to the elastic-plastic FE theory and the characters of cold roll forming. The author takes the pocket wave experiment , which has been carried out by Japanese Prof. Hirish Ona, as the criterion and confirms the feasibility of simulation model.
The author simulates the pocket wave occurring in wide range section forming with the model established above. According to the simulation results, the author analyzes the mechanism and characters of pocket wave, and examines the hypothesis on mechanism of pocket wave.
The author simulates the zero inner radius part in a certain project, which is offered by Korea Institute of Industrial Technology and carried out by Institute of Mechanical-electrical Engineering of NCUT. According to the simulation results, the feasibility of roller design is examined, and some advices are given. In addition, the author analyzes the moving of Neutral line when the inner radius is less than half the thickness of sheet.
Above all, the model established in this paper has been tested with examination and confirmed to be right and effective, and it can simulate the process of cold roll forming successful. The results and the conclusions in this paper can offer reference and experience for the cold roll forming industries research, design and production.
Key words: cold roll forming, FEM, simulation, MSC.Marc, wide range section, zero inner radius