Analysis and Bending Amount Design of V-shaped Roller Straightening Process
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摘要: 基于弹塑性变形理论,利用ANSYS LS-DYNA建立了V形辊的七辊矫直机的三维有限元模型,对V形辊辊式矫直过程进行分析。进行了下压量的参数设计,并分析了不同下压量下,菱形型材在矫直过程中的变形及矫直后的残余应力分布规律。结果表明:菱形型材被矫直后残余应力主要分布在边界处,随着下压量的增大最大残余应力先减小后增大。通过有限元仿真确定了截面尺寸为22 mm×22 mm菱形型材的最佳下压量。结果表明:该下压量下,被矫直件矫直后的平直度满足精度要求,且仿真结果与实验结果相一致,验证了理论模型的正确性。Abstract: Based on the elastic-plastic deformation theory, three-dimensional finite element model for a seven-roll straightening machine with V-rollers was established with ANSYS LS-DYNA to analyze thestraightening process of V-shaped roller. According to the scheme of the small deformation of the bending amount, the bending amount designwas carried out. The deformation of rhomboid profile in the straightening process and the distribution of residual stress after straightening under the different bending amounts were analyzed. The results show that the residual stress distributes mainly at the boundary of diamond profile after the straightening. The maximum residual stress decreases firstly and then increases with the increasing of bending amount. The optimal bending amount of the diamond profile with a section size of 22 mm×22 mm is determined with the finite element analysis. The straightness of the profiles before and after straightening is compared through the experiments and finite element analysis. The experimental and finite element simulation results show that under the optimal bending amount, the straightness after being straightened by the straightening piece satisfies the accuracy requirement, and the simulation results are consistent with the experimental, which verifies the correctness of the theoretical model.
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表 1 上辊的压下量
辊号 2 4 6 压下量/mm 1.76 1.52 0.91 表 2 不同原始弯曲下的残余应力
原始弯曲 类型 ${\sigma _{{x}}}$/ MPa ${\sigma _{{y}}}$/ MPa ${\sigma _{{{\textit{z}}}}}$/ MPa Mise应力/MPa 无弯曲 最大值 25.44 13.34 10.81 39.67 最小值 −20.64 −14.24 11.88 0.13 小弯曲 最大值 148.2 82.19 51.05 166.6 最小值 −141.7 71.72 60.03 0.53 大弯曲 最大值 235.1 50.03 47.59 241.1 最小值 −231.8 −51.16 −49.63 0.85 表 3 不同方案下各辊压下量
组序(方案) 2号辊 4号辊 6号辊 1(小下压量值) 1.68 1.33 0.42 2(理论计算值) 1.76 1.52 0.91 3(多组仿真结果) 2.76 2.32 1.64 4(大压下量值) 3.26 2.83 1.87 表 4 不同压下量矫直后的平直度
组序 压下量/mm 原始平直度/
(mm∙m−1)矫直后平直度/
(mm∙m−1)2号辊 4号辊 6号辊 1 1.68 1.33 0.42 80 8.3 2 1.76 1.52 0.91 80 9.1 3 2.76 2.32 1.64 80 4.4 4 3.26 2.83 1.87 80 5.8 -
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