基于惩罚法接触模型的Cu/Al复合板轧制界面动态复合过程数值模拟  

Numerical Simulation of Cu/Al Composite Plate Rolling Interface Dynamic Composite Process Based on Contact Model of Penalty Method

作　　者：孙其美 覃志伟 赵辰辰 孙亚波 王涛 SUN Qimei;QIN Zhiwei;ZHAO Chenchen;SUN Yabo;WANG Tao(College of Mechanical and Vehicle Engineering,Taiyuan University of Technology,Taiyuan 030024,China;Engineering Research Center of Advanced Metal Composites Forming Technology and Equipment of Ministry of Education,Taiyuan University of Technology,Taiyuan 030024,China;National Key Laboratory of Metal Forming Technology and Heavy Equipment,Taiyuan 030024,China)

机构地区：[1]太原理工大学机械与运载工程学院,太原030024 [2]太原理工大学先进金属复合材料成形技术与装备教育部工程研究中心,太原030024 [3]金属成形技术与重型装备全国重点实验室,太原030024

出　　处：《中国表面工程》2025年第1期182-194,共13页China Surface Engineering

基　　金：国家自然科学基金重大项目(U22A20188)。

摘　　要：数值模拟是金属复合板轧制过程分析的有力工具,然而目前模拟异种金属层状板冷轧复合的数值模型大多采用界面绑定或摩擦约束。难以对界面动态复合进行判定和模拟,较难反映复合板真实的应力应变场以及实现宏观翘曲、厚度比的高精度预测,并且在单道次大压下率下易出现网格畸变严重、计算不收敛等问题,从而制约了轧制复合仿真领域的融合发展。提出了一种新的数值模型,其中的Cu/Al板有限元建模部分采用一种长宽比大于等于2的细长形网格,并且改进先前复合判据在力学行为上只考虑法线方向的不足,引入了切向力限制条件,更好地描述了法向力和切向力综合作用的实际轧制复合过程。该模型可实现对40%~60%压下率区间内,2∶4、3∶3、4∶2厚度比Cu/Al板的轧制复合模拟和宏观样貌表征,同时实现对复合板翘曲度板形和轧后厚度比的高精度模拟,翘曲度的误差均小于7.40%,轧后厚度比误差一般小于10%。模型初步解决了单道次大压下率下的严重网格畸变和计算不收敛问题,此外,在评估层状金属板复合质量和进一步探究轧制复合内在作用机制等方面有良好的发展潜力。Numerical simulations are powerful tools for analyzing the rolling process of metal composite plates.However,the current numerical models for simulating the cold-rolling compounding of dissimilar metal-layered plates mostly adopt either interface binding or friction constraints.These approaches fail to accurately judge and simulate dynamic compounding at the interface,making it difficult to achieve precise predictions of the true stress-strain field,macroscopic warping,and thickness ratio of composite plates.Additionally,simulations involving high reduction rates in a single pass often suffer from severe mesh distortion and nonconvergence issues,hindering the integrated development of simulations in the field of rolling compounding.In this paper,we propose a novel numerical model to overcome these limitations.The finite element modeling of the Cu/Al plates in this model employs elongated meshes with an aspect ratio of at least 2.This improvement addresses the shortcomings of previous compounding criteria,which only considered normal forces,by incorporating tangential force constraints.This enhancement allows for a more accurate representation of the actual rolling compounding process,which involves the combined action of normal and tangential forces.The research objectives of this study are multifaceted.First,we aim to develop a robust numerical model that can accurately simulate the rolling compounding process of dissimilar metal-layered plates.Second,we seek to predict the quality of the composite metal plates in terms of their stress-strain field,warping degree,and post-rolling thickness ratio.The study's methodology involves several key steps.Initially,we developed a finite element model using elongated meshes with aspect ratios of at least 2.This choice of mesh design helps reduce mesh distortion and improves the convergence of the simulations.We then incorporated tangential force constraints into the model to address the limitations of previous models that only considered normal forces.This dual considerati

关 键 词：复合板轧制 数值模拟 惩罚接触算法 有限元法 轧制复合判据 

分 类 号：TG335[金属学及工艺—金属压力加工]