Transactions of Materials and Heat Treatment

Title：Key techniques in the numerical simulation and modeling for roller hemming of aluminum alloy sheet

Authors： Hu Xing Yang Honggang Yang Haijun Dan Wenjiao

Unit： Shanghai Dianji University Shanghai Jiao Tong University

KeyWords： aluminum alloy roller hemming numerical simulation

ClassificationCode：TG386

year,vol(issue):pagenumber：2015,40(5):42-47

Abstract：

Roller hemming is a complex process with single point continuous loading by multi-steps. The design of feasibility in the process should be completed at the early stage of the development. However, experiences or trial and error method can not meet the requirements of roller hemming process at current. In order to manage production and design processes, the key techniques in numerical simulation and modeling for roller hemming of aluminum alloy sheet were studied, which included element type, loading method and so on. The investigation shows that the computing efficiency and accuracy of numerical simulation can be assured by the minimum shell element size of 0.5 mm. For computing efficiency, the shell element S4R with the reduced integration four-node shell element of seven thickness integration points was adopted in simulation. Moreover, rolling movement simulation can be replaced by sliding with friction coefficient of zero. Furthermore, the hardening effect induced by flanging process can be neglected in the simulation of variants of contour size of parts, and pre-strain should not be ignored when the fracture of material is simulated.

Funds：

国家自然科学基金资助项目(51275296)；上海电机学院学科基础建设项目（12XKJC02）；上海电机学院青年教师科研启动基金（14QD35）

胡星(1982-)，男，博士，讲师

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