目的 为消除波纹板在辊弯成型过程中产生的波纹缺陷,对地铁波纹板在冷弯成型时常出现的残余内应力和边部波浪等问题进行了深入研究。方法 采用弹塑性变形理论并结合专业软件COPRA,建立符合生产标准的宽幅波纹板辊弯成型有限元模型,考虑材料的力学性能和实际工艺影响因素,通过对各道次成型过程的有限元仿真,提前预测成型过程中可能出现的问题,并通过调整工艺参数和优化轧辊设计进行改进。结果 仿真分析结果表明,7、8、11、12、15和16区域的应力应变值均超出了材料极限,导致板带局部应力过大,引发了材料的拉伸塑性变形,基于DTM分析结果,对6个道次的成型角度进行了重新分配,板材初始厚度为0.6 mm,经过16道次的辊压成型,弯角处的板材经历了减薄,最薄处的板厚达到了0.517 mm,减薄率为13.83%,在板材厚度减薄的工程允许范围内。通过安全系数定量分析可知,应变安全系数达到2.39,应力安全系数为1.26,验证了工艺设计的安全性。仿真预测与生产验证的关键指标相对误差均小于10%,表明仿真模型具有良好的预测精度。结论 通过对轧辊进行优化设计,并采用模具调试分析与解决策略,在冷弯成型机组上进行了生产验证,成功解决了地铁辊弯成型过程中宽幅波纹板的质量缺陷问题。该研究方法为辊弯成型提供了科学指导,不仅为宽幅波纹板的工艺设计提供了可靠依据,还为类似产品的工艺优化提供了宝贵参考。
Abstract
The work aims to conduct an in-depth study on common issues such as residual internal stress and edge waves that frequently occur during the cold roll forming of subway corrugated sheets to eliminate the corrugated defects generated during the roll forming process of corrugated sheets. Based on the elastic-plastic deformation theory and the professional software COPRA, a finite element model for the roll forming process of wide corrugated sheets that met production standards was established. Considering the mechanical properties of the material and the actual influencing factors of the process, finite element simulations for each forming pass were performed to predict potential problems in advance. Improvements were subsequently made by adjusting the process parameters and optimizing the roller design. The simulation analysis results indicated that the stress and strain values in the 7th, 8th, 11th, 12th, 15th, and 16th passes exceeded the material limits, resulting in excessive local stress in the strip and inducing tensile plastic deformation. Based on the DTM analysis results, the forming angles of these six passes were reallocated. With an initial sheet thickness of 0.6 mm, the material at the bending corners experienced thinning after 16 passes of roll forming. The minimum thickness reached 0.517 mm, representing a thinning rate of 13.83%, which was well within the allowable engineering range for sheet thinning. A quantitative analysis of the safety factors showed that the strain safety factor reached 2.39 and the stress safety factor was 1.26, thereby verifying the safety of the process design. Furthermore, the relative errors of key indicators between the simulation predictions and production measurements were all less than 10%, indicating that the simulation model possessed high prediction accuracy. By optimizing the roller design and adopting mold debugging analysis alongside corresponding solution strategies, production verification is successfully carried out on the cold roll forming unit. This successfully resolves the quality defects of wide corrugated sheets during the roll forming process for subways. The research method provides scientific guidance for roll forming, serving not only as a reliable basis for the process design of wide corrugated sheets but also as a valuable reference for the process optimization of similar products.
关键词
冷弯成形 /
波纹板 /
COPRA /
辊花 /
轧辊 /
模态仿真
Key words
cold roll forming /
corrugated plate /
COPRA /
roll pattern /
roll /
modal simulation
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基金
2024年度吉林省教育厅科学研究项目（JJKH20241782KJ）; 吉林省自然科学基金（20260102277JC）; 2024年度吉林省科技厅“科创专员（科创副总）”项目
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