Nâng cao chất lượng tạo hình uốn ống đồng sử dụng phân tích, mô phỏng bằng phương pháp phần tử hữu hạn

TAP CHi KHOA HQC & CONG NGH? CAC TRL ONG DAI HOC KV THUAT * SO 98 - 2014 NANG CAO CHAT LUONG TAO HINH UON ONG DONG SI/DUNG PHAN TICH, IMO PHONG BANG PHUONG PHAP PHAN TU"HtTU HAN FORMABILITY IMPROVEMENT OF TUBE BENDING PROCESS FOR COPPER MATERIAL JIS25A USING FEM ANALYSIS AND SIMULATION Nguyen Bii-c Todn, Pham Quoc Tuan, Nguyen Dinh Thdnh Trirdng Dai hoc Bdch khoa Hd Noi Din Tda soan 04-11-2013, cbdp nhan dang 25-12-2013 ABSTRACT To predict and improve formability of tube bending process for copper JIS25A material, geometric parameters of bending process were considered according to Taguchis odhogonal array then coupled with the finite element method (FEM) simulations First, the stress-strain curve of material was input into ABAQUS/Explicit finite element code to predict the initial results of tube bending process Three parameters vanable - the diameter of ring mandrel, distance of two rings, distance of mandrel and base were then selected to establish their effects on the quality of bending process The optimum simulation case was finally confirmed by corresponding experiment Keywords JIS25A, FEM, Taguchi method, Tube bending process TOM T A T De dw doan va cai thien qua trinh uon ong bang vat lieu ddng (JIS25A), cac tham so hinh hoc cua qua tnnh gia cong dwac phoi hap sir dung theo thuat toan mang trwc giao Taguchi va ket hap vdi phwang phap mo phong phan td hiru han (FEM) Dau tien, dwdng cong irng suat-bien dang cua vat lieu dong dirge dwa vao ph^n mSm ABAQUS/Explict de dw doan k§t qua ban dSu cua qua tnnh udn ong Cac tham so co the thay doi dwac nhw dwdng kinh vong uon, khoang each giira cac vong khoang each tir true uon t&i lam de sau dwac lira chon de danh gia anh hwang eua chung den chat lirgng tao hinh san phSm Tnrdng hap toi wu sau qua trinh mo p idng se dwgc sir dung de nang cao chat Iwang san pham cuoi cung san xuat lir khda: JIS25A FEM, phuo'ng phap Taguchi, tao hinh uon ong i GIOI THIEU Cac chi tiet ong tru uon dong vai trd quan trpng cac bo phan d td, hang khdng, dudng ong dan khi-dan dau va cac nganh cdng nghiep khac [1] Nhieu md hinh va phuang phap dang dugc sir dung de gia cdng tao hinh cho cac chi tiet dang Tuy vay cac hien tugng nhu nhan, rach va bep gap phai tao hinh cho cac dng c6 ti so dudng kinh-dd day Idn bo^c v§t lieu ong la cac vat heu deo nhu ddng [2] (Hinh 1) Cac nghien cuii ve cac hien tugng neu tren va phuang phap sir dung tao hinh udn dng da dugc nhieu tac gia cong b6 [3],[4] MSc dii the doi vdi tao hinh cac dng cd mdng va lam tir vat lieu deo nhu ddng van gap phai cac hien tugng xSu tren Do dd, nghien ciiu nham dua mo hinh va tdi iru hoa tham so cho qua trinh lao hinh udn ong vat lieu ddng sir dung phuang phap phan tu h&u ban (FEM) [5],[6] Hinh I Cdc sdn phdm hi nhdn rdch sau lao hinh Cac phan mem md phdng sd sir dung phuong phap phan tir h\iu han (FEM) nhu ABAQUS/ Explicit [7] to la mgt cong cu hiJu hieu de xay dung md hinh vat ly qua trinh tao TVPCHI KHOA HOC & CONG \ ( ; H E CAC TRIONG DAI HOC KY Till \T * SO 98-2014 hinh va du doan ket qua ciia san pham Ciing vdi thuat toan mang true giao Taguchi [8], sii' dung mo phong s6 da riit ngdn thdi gian va tang hieu qua qua trinh nghien ciiu va du doan ket qua Dd la ly phuang phap dugc sir dyng nghien ciiu ciia nhom tac gia M PHONG SU DUNG PHUONG PHAP PHAN TU HUU HAN 2.1 Vat lieu lam ong Dua tren cac nghien ciiu ciia cac tac gia trudc ve van de cung nhu vat lieu thuc te ciia ing, ta co dugc cac thong so eg ban va dirdng cong ling sudt biin dang ciia vat lieu [2] Bdng } Cdc ddc tinh cua vdi lieu ldm ang Vat lieu Khfli lugng ri6ng(p,A"g/»jm"') Mo dun dan hoi {E.N I inn?) He so Poisson a-,1 (MPa) Dong (JIS25A) 8,95.10-6 120 000 0,33 72 0.00 i ^w, Phuong trinh dudng cong bien dang deo da dupe nhieu tac gia nghien ciru trudc dd [9 10], nghien cim phudng trinh dugc ap dung nhu sau: (I) CT, - irng suat tai diem khao sat(MPa) f, - bien dang tai diem khao sat CT,,, - irng suat tai diem bien di1 deo ciia vat lieii(MPa) £,,, - biin dang tai diem biin d ig deo ciia vat m - sd mu ciia dudng cong Trong bai bao nay, phuang trinh biin dang deo ung vdi vat lieu lam dng sau str dung tuang thich dudng cong bang phuang phap binh phuang nho nhat dugc md ta phuang trinh (2) Dudng cong ung suat bien dang ciia vat lieu thir nghiem dugc the hien Hinh CT = (2) Hinh Dirdng cong irng suat-bien dgng deo cua vgl li?u ldm ong 2.2 Xay dung md hinh md phdng so Mo hinh chi tiet can gia cdng va cdc bo phan gia cdng va phu trp dugc xay dung tren phan mem Abaqus 6.10.1 vdi kich thudc mat cat ong gia cdng la (^15.88/Mm vaday 1mm Mdhinh uon ong gian don chi co true udn ket hgp vdi tam dt v& cdc tam chan trudc tien dupe sir dung de kiem tra kha nang tao hinh cho san pham nhu Hinh -J j;,^jk^ii^ i S.ls.^ii'J.LE-^V^^ST-'-'i-"''^'-^-'"-^'^' Taiii chan !-i'? Timi Lie Hinh Mo hinh uon dng ban ddu (True udn duoc dua vdo theo hirang mid ten) Cac ket qua md phdng cho m6 hinb thu nghifm ban dSu vdi cdc tham s6 md phong \h dudng kinh true udn (D,) = 6,6 mm va khoang cdc tir dau true uon den tdm ban kinh cong ciia tdm de (e) = 5,0 mm duac chi Hinh Ta cd the de dang nhan thdy phdn dng bj meo, hi nhan, sai sd hinh dang hinh hgc viing u6n Id rat Ion Qua qua trinh nghien ciiu phdn tich, cdc tac gia dua y tudng khac vi bd phan dimg di uon 6ng; dd la them vdo cdc vong udn cung vdi true udn de giam thieu dp meo va cai thien chiiu day thdnh dng tai viing bj keo ciia sdn phdm nhir dugc the hien Hinh (a) Kit qua md phong dugc chi Hinh (b) TAP CHi KHOA HOC & CONG NGHE CAC TRUOTVG DAI HOC KV THUAT 4> SO 98 - 2014 ciia dau true udn vdi tam ban kinh cong ciia tam de e (mm); (C) tuong irng vdi khoang each giOa cac vdng udn dr (mm) MANG TRUC GIAO TAGUCHI Hinh Ket qud mo phong trudng hap ban ddu r I ; 1^ Khi ong dugc tao hhih tir chuyen dong ciia true uon va cac vdng uon, xu hudng pha hiiy xay dvimg bi keo ciia ong Id iing suat bien dang keo tai rat Idn; neu bien dang Idn hon gia tri gidi han cho phep se dan den hien tupng pha hiiy deo Trong xu hudng nhan xay tai vimg nen ciia vat lieu, se lam cho dng khdng dat dugc dp tran can thiet Khi cdc thong so dirge lira chpn thay doi dp !dn ii'ng suat bien dang va dp day tai cac vLing quan tam cimg thay doi theo Do chinh la y tudng cho viec cdi thien kha nang tao hinh ciia qua trinh uon ong Van de se dan gidn ban ta su dung phuang phap Taguchi de khao sat anh hudng ciia cac thdng so tren Ti le S/N(signal-to-noise) [7] xac dinh qua cong thirc: n, = - l 1og(At-) (2) At- ti so day giua viing mong nhat va day nhat r-^ , , (b) Hinh De xudt mo hinh true uon vd cdc vong uon a), ket qud mo phdng b) do- D, — dudng kinh true udn, e — khodng cdch tir ddu true uon tai tdm bdn kinh cong cita Idm de, d,- — khodng cdch giua cdc vdng udn Ket qud mo phong cho thay dng sau udn da cd hinh dang tot hon so vdi chua dua m6 hinh, vdy dd day ong va hinh dang cua ong sau bien dang tao hinh van chua duoc toi uu hoa Do sau de xuat mo hinh udn dng, cac tham sd tao hinh dugc can nhac de kiem tra anh hudng ciia chiing tdi chat lugng san pham Qua qua trinh mo phdng, nhom tac gid nhan thay cac tham sd sau anh hudng Idn den chat lugng tao hinh (Hinh (a)): (A) tuang img vdi dudng kinh ctia true udn va vong u6n Dr (mm); (B) tuong dng vdi khoang cdch tuong d6i Khi At cang Idn thi dp day ong cang dong deu va chat lugng gia cdng tao hinh cang tdt, At cang Idn ti le S/N cang nho Do vay ti le S/N nho nhat thi chdt lirgng gia cong tao hinh la tot nhat Ci day, anh hudng ciia cac tham sd dudng kinh vdng uon (Dr), khoang each dau true tdi tam ban kinh cong ciia tam de (e) vd khodng each giu'a cac vong uon (dr) tdi chdt lupng san phdm se dugc tham dinh Bang Ii6t ke cac cap dp lua chon cua cdc tham s6 Bdng Cdc he so vI cdp cua chiing Irong md phong Tham so A(D,) B(e) C(d,) 6,6 3,5 4,0 Cap 6,5 4,5 4,5 6,4 5,5 5,0 Trong qua trinh md phong co cap dp ciia tii'ng tham sd dugc lua chon nen mang true giao L9 se dugc dimg de thiet ki quy hoach thuc nghiem Khi dd tdi thieu thi nghiem la can thiit cho viec kiem tra anh hudng ciia cac tham s6 thay ddi qua trinh ino phong Viec sii dung thuat todn true giao Taguchi se giam so lugng TAPCIHKH0AH0C&C0NGNGHECACTRU6NGDAI HQCKV im \ r * S698-2014 thiet ke thuc nghiem tir 27 xudng cdn thi nghiem Cac he sd ciia thi nghiem dugc the hien bdng Trong nghien cim nay, ta chi xet anh hudng ddc lap cua cdc tham sd ma khdng cd sir tuong tdc rang budc ciia cac tham sd vdi Bang 3- Bdng cdc trudng hop md phong Iheo thudt todn Taguchi Thi nshiem 7 S C(d.) (mm) 1(4,0) 2(4,5) 3(5,0) 2(4,5) 3(5,0) 1(4,0) 3(5,0) 1(4,0) 2(4,5) B(e) (mm) 1(3.5) 2(4,5) 3(5,5) 1(3,5) 2(4,5) 3(5,5) 1(3,5) 2(4,5) 3(5,5) A(D,) (mm) 1(6,6) 1(6,6) 1(6,6) 2(6,5) 2(6,5) 2(6,5) 3(6,4) 3(6,4) 3(6,4) KET QUA MO PHONG VA THAO LUAN Bang the hien ket qua md phong ve ti so d6 ddy (At) tai vi tri mong nhat (tm,„) va day nhat (t,„ax) ti so nhiiu {^,) ciia cdc trudng hgp theo thudt toan Taguchi Dua tren phuang phap Taguchi, phdn tich phuang sai (ANOVA) dugc sir dung de danh gia anh hudng cac tham so Bang the hien tdng hpp ket qua tinh todn vdi tdng binh phuang dugc tinh theo cdng thiic: 3{m^^ -nif +3(/»,i -/»)" +3(m^3 -mf Kit qua tinh todn cho thdy khoang cdch giSa cac vdng udn (d,) anh hudng nhiiu nhat tdi chdt lugng sdn phdm vdi 55.2% Trong dd anh hudng cua cdc thdng sd dudng kinh vdng udn (Dr) va khoang each tir true u6n tdi tam bdn kinh cong ciia tdm di (e) it han, idn hrgt la 35.3% vd 9.5% Vi vay khoang cdch gi&a cac vdng uon (dr) la tham sd anh hudng quan trpng nhdt den chdt lugng tao hinh qud trinh mo phdng Cung dua tren kit qua tinh todn a bang 5, ta chpn duac bg thSng sd t6i uu irng vdi cdp dg ciia cac thdng sd cd ti sd S/N trung binh nlio nhdt la A3B3C1 Hinh the hien ket qua mo phdng ling voi bd thdng sd dugc chpn toi uu; ket qua thu dugc la dp day chd mong nhat 0,772 mm, dp ddy chd day nhdt 1,265 mm Do dd, su dung thuat toan Taguchi vdo mo phong phdn tir huu ban da dua dugc dieu kien t^o hinh cai thien kha ndng tao binh ciia san phdm Kit qud chi rdng thdng sd ciia dilu kien toi uu la dudng kinh vong uon (D,) = 6,4 mm, khoang cdch tir dau true udn tdi tdm bdn kinh cong ciia tdm de (e) - 5,5mm, khodng each giira cdc vong uon (d,) = mm f (3) m Id gid tri trung binh ciia // , a) m - - ^ ^ 7 , - , ; „ ; ^ , - - ^ ( ; ; ^ ) J d gid trj " ^ 1=1 v-lflSI^X ,=1 trung binh ciia r| tuong ung vdi tham so j (j = A, B, O v a cdp dpi (1=1,2,3) [7] Bang Kel qua md phong theo mdng true giao Taguchi STT tmm (mm) A; n.{dB) 0.549 0,536 0,524 0,541 0,542 0.593 0,545 0,606 0,579 5,209 5,417 5,613 5,336 5,320 4,539 5,272 4,351 4,746 (mm) 7 0,713 0,675 0.682 0,699 0,698 0.756 0,710 0,778 0,754 1.298 1,258 1,302 1,292 1,288 1.275 1,302 1,284 1,301 Hinh Chieu ddy thdnh a), sai sri hinh ddng hinh hoc mdi cdl AA b) sau tdi uu Hinh Sdn phdm thuc nghiem vdi trudng hap tdi iru (AiBiCO T^? CHi KHOA HQC & CONG NGHE CAC TRUftNG DAI HOC KV THUA r SO 9; Hinb Ld kit qud thuc nghiem tuong dng vdi ket qua md phong, khdng cd hien tugng pha hiiy deo xdy viing k^o vd hien tupng nhan xuat hien vimg nen ciia sdn pham K £ T LUAN De cdl thien va nang cao chat lupng san pham ciia qua trinh udn dng dong, cac md phdng sd FEM ket hop cimg thuat todn mdng true giao Taguchi dd dua dupe cac thong sd anh hudng tdi chat luang san pham, Ket qua thu dupe chi rang khoang cdch giira cac v6ng udn anh hudng Idn nhat den chat luong tao hinh san pham Cdc tham sd dugc lira chon gom: dudng kinh vong udn Dr ^ 6,4 mm, khoang each tii' dau true uon tdi tam ban kinh cong cua tdm de e = 5,5 mm, khoang each giua cac vdng uon dr = mm dupe du dodn Id tao dugc san pham co khd ndng tao hinh tot nhat LOI CAM ON: Nghien ciiu dupe tai trg bdi Quy phat trien khoa hpc va cong nghe quoc gia (NAFOSTED) di tai ma sd "107.022013.0 r \ Bang Tong hap vd phdn lich dnh huang cdc Iham so (* gtd Iri loi iru) Cac tham so A(D,) (mm) B(e) (mm) C(d,)(mm) Tatca Ti so S/N trung binh cua ttmg citp 5,065 5.413 4,790* 5,272 5,029 4,966* 4,640* 5,166 5,402 Tong binh phuong 0,585 0,157 0,916 1,658 Phan bo 0,353 0,095 0,552 TAI LIEU THAM KHAO H Yang, Y Lin, S Zhichao: Advanced plastic processing technology and research progress on tube fonning, J Plasticity Eng Vol (2), pp 86-88 (2001) Konings R.J.M, Comprehend nuclear materials, p 667, Elsevier Ltd, 2012 N.C Tang: Plastic deformation analysis of tube bending, Int j press Vess, Pip Vol 77(12), pp 751-759(2000) J.B Yanget al : The tube bending technology of a hydroforming process for a automotive part, J Mat Proc Tech Vol 111(1-3), pp 175-18! (2001) N Due-Toan, B Tien-Long: Numerical analysis to determine die radius and bending angle in rollbending process for sheet material, J Scie Tech No.88b, pp 84-90 (2012) N Duc-Toan, J G Park, H.J Lee and Y.S Kim- Finite element method study of incremental sheet forming for complex shape and its improvement, Proc Inst Mech Eng., Part B: J Eng Manuf, Vol 224, pp 913-924, (2010) Taguchi, On-line Quality Control during Production Japan Standard Association, Tokyo, 1981 Hibbit D., Karisson B and Sorensen, P ABAQUS User's Manual, Ver 6.10 I ABAQUS Inc (2008) Nguyen Duc-Toan, Hoang Vinh-Sinh, Banh Tien-Long: A Modification of Johnson-Cook Model to Predict Stress-Strain Curves of Boron Steel Sheets in Elevated Temperatures JOURNAL OF SCIENCE & TECHNOLOGY, No83B-2011, pp 113-118, (2011) 10 Nguyin Diic Toan Ngiiygn Duy Thanh, Nguyln Tiin Ddng, Nguyin Thi H6ng Minh Banh Tiln Long: De xudt phirong trinh dudng cong img sudt-biin dang cho hgp kim ma gie az31 b tai cac nhiet cao Tap chi khoa hgc va cdng nghe, No 89-2012, pp 0868-3980, (2012) Dia chi hen he: Nguyln Ddc Toan - Tel: 0988693047; E-mail: toan.nguyenduc(ghiist.edu.vn Trudng Dai hgc Bdch khoa Hd Ngi  ... xdy viing k^o vd hien tupng nhan xuat hien vimg nen ciia sdn pham K £ T LUAN De cdl thien va nang cao chat lupng san pham ciia qua trinh udn dng dong, cac md phdng sd FEM ket hop cimg thuat todn... Long: De xudt phirong trinh dudng cong img sudt-biin dang cho hgp kim ma gie az31 b tai cac nhiet cao Tap chi khoa hgc va cdng nghe, No 89-2012, pp 0868-3980, (2012) Dia chi hen he: Nguyln Ddc Toan