بررسی عددی و تجربی اثر گرمای موضعی روی کاهش عیب برگشت‌فنری در فرایند شکل‌دهی غلتکی انعطاف‌پذیر

نوع مقاله : مقاله پژوهشی

نویسندگان

1 کارشناس ارشد، مهندسی مکانیک، دانشگاه تربیت دبیر شهیدرجایی، تهران، ایران

2 استادیار، گروه ساخت و تولید، دانشگاه تربیت دبیر شهیدرجایی، تهران، ایران

3 استادیار، گروه مهندسی مکانیک، دانشگاه فنی و حرفه‌ای، تهران، ایران

چکیده

یکی از محدودیت‌های شکل‌دهی غلتکی سنتی ساخت قطعات با مقاطع ثابت است بنابراین فرایند شکل‌دهی غلتکی انعطاف‌پذیر به‌منظور تولید قطعات با سطح مقطع متغیر ایجاد شد. مهم‌ترین عیوب این فرایند شامل، تابیدگی کف، برگشت‌فنری، انحراف از موقعیت مطلوب لبه، چین‌خوردگی لبه و پارگی در گوشه‌ها می‌باشد. در این مقاله به بررسی عددی و تجربی اثر حرارت‌­دهی به ورق در حین فرایند شکل‌دهی غلتکی انعطاف‌­پذیر روی عیب برگشت‌فنری پرداخته شده است. بدین منظور شبیه‌سازی اجزای محدود ترمومکانیکال فرایند در نرم‌افزار آباکوس انجام شد. آزمایش‌­های تجربی با استفاده از دستگاه شکل­‌دهی غلتکی انعطاف­‌پذیر ساخته شده در دانشگاه شهید رجایی تهران به همراه سازوکار حرارت­‌دهی موضعی الحاقی در پنج دمای 25، 100، 200، 300 و 400 درجه سانتی‌گراد به‌منظور صحت سنجی نتایج شبیه­‌سازی انجام شد. برای اندازه­‌گیری دمای ورق، از ترمومتر لیزری استفاده شد. برای جلوگیری از بازتاب نور لیزر و خطا در محاسبه دما، ورق به‌وسیله پوشش‌­دهی کربن مات گردید. نتایج نشان داد که با افزایش دما برگشت‌فنری نسبت به شکل‌­دهی در دمای محیط در هر دو جنس آلومینیوم کاهش یافت و با افزایش استحکام تسلیم، برگشت‌فنری افزایش یافت. با افزایش دما تا 400 درجه سانتی­‌گراد نسبت به دمای محیط، برگشت‌فنری در ضخامت 1 و 5/1 میلی‌متر، به ترتیب 5/33 و 2/41 درصد کاهش پیدا کرد؛ همچنین مقایسه نتایج شبیه­‌سازی و تجربی تطابق خوبی را نشان داد.

کلیدواژه‌ها

عنوان مقاله [English]

Numerical and experimental investigation of the effect of local heating on the reduction of the spring back defect in the flexible roll forming process

نویسندگان [English]

  • Mehdi Shamshiri 1
  • Valiollah Panahizadeh 2
  • Yaghoub DadgarAsl 3
1 Department of Mechanical Engineering, Shahid Rajaee Teacher Training University, Tehran, Iran
2 Department of Mechanical Engineering, Shahid Rajaee Teacher Training University, Tehran, Iran
3 Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran
چکیده [English]

One of the limitations of traditional roll forming is the production of parts with fixed cross-sections, so the flexible roll forming process was created to produce parts with variable cross-sections. The most important defects of this process, include warping, spring back, deviation from the desired position of the edge, wrinkling of the edge, and fracture in the corners. In this paper, the numerical and experimental investigation of the effect of heating the sheet during the flexible roll-forming process on the spring back defect was discussed. For this purpose, the simulation of the thermomechanical finite elements of the process was carried out in Abaqus software. Experimental tests were conducted using a flexible roller forming machine made in Shahid Rajaee University of Tehran along with additional local heating mechanisms in five temperatures 25, 100, 200, 300, and 400 to validate the simulation results. A laser thermometer was used to measure the sheet temperature. To prevent laser light reflection and error in temperature calculation, the sheet was matted by carbon coating. Results showed that with the increase in temperature, the spring back compared to forming at ambient temperature decreased in both types of aluminum, and with the increase of yield strength, the spring back increased. By increasing the temperature up to 400°C compared to the ambient temperature, the spring back in thickness 1mm and 1.5mm, decreased by 33.5 and 41.2%, respectively; also, the comparison of simulation and experimental results showed a good agreement.

کلیدواژه‌ها [English]

  • Spring back
  • Flexible roll forming
  • Local heating

مراجع

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