Chen Peng, Lu Shihong
College of Mechanic and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, 210016, China.
Heliyon. 2024 Nov 13;10(23):e40166. doi: 10.1016/j.heliyon.2024.e40166. eCollection 2024 Dec 15.
This study investigates the surface forming mechanism in four-roll flexible rolling forming processes, addressing issues of low efficiency and significant residual stresses, particularly when dealing with lightweight high-strength materials such as LY12 aluminum alloy. Initially, the study systematically analyzes the variation in sheet curvature radius under different forming methods, considering the separate and combined actions of side rolls and flexible rolls in the pre-bending forming process. Subsequently, actual forming data is obtained by conducting four-roll flexible rolling forming on LY12 aluminum alloy experimental material. A numerical model is then established using finite element analysis to simulate key parameters such as stress, deformation, and temperature distribution during the forming process. Adjustments to process parameters are made based on the analysis of numerical simulation results to achieve optimized forming. Additionally, the uniformity of four-roll flexible rolling forming of LY12 aluminum alloy with different hardness and thickness is examined. The research findings reveal that optimizing process parameters leads to a 14.95 % improvement in forming accuracy and a 30.52 % reduction in residual stress for LY12 aluminum alloy sheets, significantly enhancing product quality and efficiency. This study not only deepens the understanding of the four-roll flexible rolling forming process but also provides a feasible optimization parameter scheme. The results offer specific guidance for the application of lightweight high-strength materials such as LY12 aluminum alloy in actual production, thereby providing important technical support for improving forming efficiency and quality.
本研究探讨了四辊柔性滚压成型过程中的表面形成机制，解决了效率低下和残余应力显著的问题，特别是在处理诸如LY12铝合金等轻质高强度材料时。首先，该研究系统地分析了不同成型方法下板材曲率半径的变化，考虑了预弯曲成型过程中侧辊和柔性辊的单独作用与联合作用。随后，通过对LY12铝合金实验材料进行四辊柔性滚压成型获得实际成型数据。然后利用有限元分析建立数值模型，以模拟成型过程中的应力、变形和温度分布等关键参数。根据数值模拟结果的分析对工艺参数进行调整，以实现优化成型。此外，还考察了不同硬度和厚度的LY12铝合金四辊柔性滚压成型的均匀性。研究结果表明，优化工艺参数可使LY12铝合金板材的成型精度提高14.95%，残余应力降低30.52%，显著提高了产品质量和效率。本研究不仅加深了对四辊柔性滚压成型过程的理解，还提供了可行的优化参数方案。研究结果为LY12铝合金等轻质高强度材料在实际生产中的应用提供了具体指导，从而为提高成型效率和质量提供了重要的技术支持。
