工程科学学报.第42卷，第6期：769-777.2020年6月 Chinese Journal of Engineering,Vol.42,No.6:769-777,June 2020 https://doi.org/10.13374/j.issn2095-9389.2019.06.21.001;http://cje.ustb.edu.cn 铝合金管材6061自由弯曲成形工艺仿真及优化 李玉森，岳振明四，妥之或，闵鑫瑞，高军 山东大学（威海）机电与信息工程学院，威海264209 ☒通信作者，E-mail:yuezhenming@sdu.edu.cn 摘要金属管材是工业领域中结构承重、输送气体和液体的重要部件.自由弯管成形技术有助于实现管件生产的高精度、 高性能、高效率和数字化，其精度控制理论和成形技术的研究具有重要的工业应用价值.本文选择直径30mm壁厚2.0mm 的铝合金管材6061为仿真优化对象，通过相关基础实验获得材料的基本力学数据，用于仿真模型参数的表征.同时，结合管 材压弯实验验证本构模型成形预测的有效性.在完成仿真模型表征和验证的基础上，对铝合金管材的自由弯曲成形过程进 行仿真模拟，分析对比了影响自由弯曲成形的各工艺参数，确定了该工况下最优的移动模与管材间隙大小、摩擦系数和进给 速度等.该研究有助于优化管材空间自由弯曲成形工艺，具有一定的工业应用价值. 关键词铝合金管材：自由弯曲成形：有限元仿真：参数优化：成形质量 分类号TG386.1 Simulation and optimization of the free bending process of aluminum alloy 6061 pipe LI Yu-sen,YUE Zhen-ming,TUO Zhi-yu,MIN Xin-rui,GAO Jun School of Electrical and Information Engineering,Shandong University,Weihai 264209,China Corresponding author,E-mail:yuezhenming @sdu.edu.cn ABSTRACT Metal pipes are the important components of structural load-bearing and conveying gas or liquid in the industrial field. However,the final forming profile obtained with the traditional bending process highly depends on the forming mold;the forming profile is simple,but the mold cost is relatively expensive.Thus,it is difficult for wide promotion on the bent pipe with a complex profile,especially for small batch production.The free bending process as a method of solving this problem is attracting a lot of attention.This process can achieve precision forming of the pipe without a forming mold.The pipe can be bent into different radii by adjusting the relative positions of the fixed die and mobile die.This process not only reduces the manufacturing cost but also improves the forming quality.The development of the free bending process will help to achieve high precision,high performance,high efficiency, and digitization of the industrial production of the metal pipes.In this study,an aluminum alloy 6061 pipe with a diameter of 30 mm and wall thickness of 2.0 mm was chosen.Its mechanical parameters were obtained by a tensile test of the axial and circumferential specimens of the pipe,and the obtained parameters were used for the parameter characterization of the chosen constitutive model. Meanwhile,a press bending test was carried out to validate the chosen model.Afterward,the pipe space free bending process was simulated by the finite element method,and the results were analyzed.Finally,the optimal values of the process parameters,including the shape of the mobile die,the size of the clearance of the mobile die and pipe,the frictional coefficient,and the feed speed of the pipe, were determined.This study has a great significance in the application of pipe space free bending forming process. KEY WORDS aluminum alloy pipe;free bending forming;finite element simulation;parameters optimization;forming quality 收稿日期：2019-06-21 基金项目：国家自然科学基金资助项目(51605257.51975327)：国家博士后科学基金资助项目(2018M642652):山东大学青年学者未来计划 资助项目(2017 WHWLJH06)铝合金管材 6061 自由弯曲成形工艺仿真及优化 李玉森，岳振明苣，妥之彧，闵鑫瑞，高    军 山东大学（威海）机电与信息工程学院，威海 264209 苣通信作者，E-mail：yuezhenming@sdu.edu.cn 摘    要    金属管材是工业领域中结构承重、输送气体和液体的重要部件. 自由弯管成形技术有助于实现管件生产的高精度、 高性能、高效率和数字化，其精度控制理论和成形技术的研究具有重要的工业应用价值. 本文选择直径 30 mm 壁厚 2.0 mm 的铝合金管材 6061 为仿真优化对象，通过相关基础实验获得材料的基本力学数据，用于仿真模型参数的表征. 同时，结合管 材压弯实验验证本构模型成形预测的有效性. 在完成仿真模型表征和验证的基础上，对铝合金管材的自由弯曲成形过程进 行仿真模拟，分析对比了影响自由弯曲成形的各工艺参数，确定了该工况下最优的移动模与管材间隙大小、摩擦系数和进给 速度等. 该研究有助于优化管材空间自由弯曲成形工艺，具有一定的工业应用价值. 关键词    铝合金管材；自由弯曲成形；有限元仿真；参数优化；成形质量 分类号    TG386.1 Simulation and optimization of the free bending process of aluminum alloy 6061 pipe LI Yu-sen，YUE Zhen-ming苣 ，TUO Zhi-yu，MIN Xin-rui，GAO Jun School of Electrical and Information Engineering, Shandong University, Weihai 264209, China 苣 Corresponding author, E-mail: yuezhenming@sdu.edu.cn ABSTRACT    Metal pipes are the important components of structural load-bearing and conveying gas or liquid in the industrial field. However,  the  final  forming  profile  obtained  with  the  traditional  bending  process  highly  depends  on  the  forming  mold;  the  forming profile  is  simple,  but  the  mold  cost  is  relatively  expensive.  Thus,  it  is  difficult  for  wide  promotion  on  the  bent  pipe  with  a  complex profile,  especially  for  small  batch  production.  The  free  bending  process  as  a  method  of  solving  this  problem  is  attracting  a  lot  of attention. This process can achieve precision forming of the pipe without a forming mold. The pipe can be bent into different radii by adjusting the relative positions of the fixed die and mobile die. This process not only reduces the manufacturing cost but also improves the forming quality. The development of the free bending process will help to achieve high precision, high performance, high efficiency, and digitization of the industrial production of the metal pipes. In this study, an aluminum alloy 6061 pipe with a diameter of 30 mm and wall  thickness  of  2.0  mm  was  chosen.  Its  mechanical  parameters  were  obtained  by  a  tensile  test  of  the  axial  and  circumferential specimens  of  the  pipe,  and  the  obtained  parameters  were  used  for  the  parameter  characterization  of  the  chosen  constitutive  model. Meanwhile,  a  press  bending  test  was  carried  out  to  validate  the  chosen  model.  Afterward,  the  pipe  space  free  bending  process  was simulated by the finite element method, and the results were analyzed. Finally, the optimal values of the process parameters, including the shape of the mobile die, the size of the clearance of the mobile die and pipe, the frictional coefficient, and the feed speed of the pipe, were determined. This study has a great significance in the application of pipe space free bending forming process. KEY WORDS    aluminum alloy pipe；free bending forming；finite element simulation；parameters optimization；forming quality 收稿日期: 2019−06−21 基金项目: 国家自然科学基金资助项目（51605257，51975327）；国家博士后科学基金资助项目（2018M642652）；山东大学青年学者未来计划 资助项目（2017WHWLJH06） 工程科学学报，第 42 卷，第 6 期：769−777，2020 年 6 月 Chinese Journal of Engineering, Vol. 42, No. 6: 769−777, June 2020 https://doi.org/10.13374/j.issn2095-9389.2019.06.21.001; http://cje.ustb.edu.cn