工程科学与技术2025，Vol.57Issue(3)：310-318,9.DOI:10.12454/j.jsuese.202400809
基于双线性强化与幂强化的多辊矫直工艺计算模型
Calculation Model of Multi-roll Straightening Process Based on Bilinear Hardening and Power Hardening
摘要
Abstract
Objective With the development of new materials,increasing complexity in material properties has made it more difficult to define accurate straightening processes.The discrepancy between the assumptions of traditional ideal material models and actual material behavior has made ac-curate modeling a core issue in straightening process calculations.To more precisely describe the elastic-plastic behavior of different materials,a multi-roll straightening process model was established based on the curvature integral method,and the effects of bilinear and power hardening co-efficients on the process were analyzed.The goal is to support the development of straightening techniques for new materials and provide a theo-retical basis for intelligent straightening and optimal design of straightening machines. Methods Three material models—ideal elastic-plastic,bilinear hardening,and power hardening—were selected,and the curvature-moment(M-K)relationships for these materials during bending were derived.Using these relationships and curvature integration,a mathematical model for the multi-roll straightening process was developed.A least squares algorithm was employed to solve the nonlinear equations iteratively,enabling accurate straightening calculations.To evaluate the applicability of different material models,five straightening schemes were designed,corre-sponding to plasticity rates of 33.4％,50.0％,66.7％,75.0％,and 80.0％.The influence of various hardening coefficients on curvature and plastic-ity during straightening was investigated.High-strength steel Q690 was used for experimental validation,with all three material models being im-ported into the multi-roll straightening model.The results were compared with both experimental data and finite element simulations to assess model accuracy. Results and Discussions Residual curvature was calculated under five straightening schemes and for hardening coefficients(0.1,0.2,0.3,0.4,0.5).The results show that as the bilinear and power hardening coefficients increase,the residual curvature error relative to the ideal elastic-plastic model also increases.Specifically,for bilinear hardening,the residual curvature errors were 0.253,0.506,0.759,1.013,and 1.266;for power hardening,they were 0.145,0.308,0.489,0.692,and 0.919.The bilinear model shows a linear increase in error,while the power model dis-plays a nonlinear pattern.The magnitude of the hardening coefficient affects only the degree of curvature error,not the underlying behavior or ma-terial applicability.When the coefficient is fixed at 0.1,curvature changes across the five straightening schemes were analyzed.The results show that with increasing reduction,the error between hardened and ideal models increases.Particularly in schemes four and five,commonly used in practice,the residual curvature error for the ideal model is 6.06％,whereas for the power model it is 13.57％.As both the strengthening coeffi-cient and reduction increase,differences in plasticity between hardened and ideal models become more pronounced.For example,with a coeffi-cient of 0.5,the plasticity deviation is 14.26％for the bilinear model and 12.61％for the power model.If the target plasticity is 80％based on the ideal model,the actual plasticity of the hardened model is closer to 70％,potentially leading to insufficient bending and reduced product quality.In terms of straightening force,the ideal model yields a unidirectional force of 434.4 kN,the bilinear model 512.7 kN,and the power model 478.3 kN.The experimental result is 462.2 kN,and the theoretical value for the power model is 483.7 kN.The 4.65％error for the power model highlights the importance of selecting an accurate material model. Conclusions The study shows that as the bilinear and power hardening coefficients η and m increase,material elastic recovery becomes more sig-nificant.Recovery has a linear relationship with the bilinear coefficient and a nonlinear one with the power coefficient.Both hardening models show reduced plastic deformation under equal pressure,leading to a weaker straightening effect.For example,the power model—more consistent with the tensile stress-strain curve—shows a 4.65％error between theory,experiment,and simulation for total straightening force.Selecting an ap-propriate material model based on specific material characteristics is crucial to ensure accuracy and efficiency in the straightening process.This research provides theoretical support for the development of straightening technology for new materials.关键词
辊式矫直/材料模型/曲率积分/ABAQUSKey words
roller straightening/material model/curvature integral/ABAQUS引用本文复制引用
朱晓宇,成子兴,王效岗,韩培胜..基于双线性强化与幂强化的多辊矫直工艺计算模型[J].工程科学与技术,2025,57(3):310-318,9.基金项目
国家重点研发计划项目(2018YFA0707304) （2018YFA0707304）
