Mo Phong Mot So Qua Trinh Gia Cong AP Luc

I HC QUC GIA THNH PH H CH MINH
TRNG I HC BCH KHOA

KHOA KHOA HC NG DNG
B MN C K THUT
---------------o0o---------------
LUN VN TT NGHIP
MO PHONG MT S QU
TRNH GIA CNG P LC
GVHD: PGS.TS. TRNG TCH THIN

SVTH: TRN KHOA LUT
MSSV: K0801199
Tp H Ch Minh, 01/2013
GVHD: PGS.TS. Trng Tch Thin ii

SVTH: Trn Khoa Lut
I HC QUC GIA TP.HCM Cng ha x hi ch ngha Vit Nam
TRNG I HC BCH KHOA c lp T do Hnh phc
***** *****
NHIM V LUN VN TT NGHIP
Khoa: KHOA HC NG DNG

B mn: C K THUT
H v tn: TRN KHOA LUT MSSV: K0801199
Ngnh : C K THUT Lp: KU08CKT1
1. u lun vn
M PHNG MT S QU TRNH GIA CNG P LC
2. Nhim v (yu cu v ni dung ban u):

- Tm hiu qu trnh dp su v gia cng bng thy lc.
- Nghin cu tm hiu l thuyt do.
- Thc hin tnh ton m phng hai qu trnh dp su v gia cng thy lc co T
bng phng php phn t hu hn s dng chng trnh ANSYS/LS-
DYNA v chng trnh HYPERVIEW phn tch kt qu.
- Kho st cc s thay i tham s hnh hc v ch ti ln kt qu bi ton.
- Kim nghim cc cng thc thit k v so snh vi kt qu thc t, t
a ra kt lun v kin ngh.
3. Ngy giao nhim v: 05.09.2012.
4. Ngy hon thnh nhim v: 27.12.2012.
5. H v tn ngi hng dn: PGS.TS. Trng Tch Thin.
Hng dn 100%.
Ni dung yu cu LVTN c thng qua b mn.

Ngy 05 thng 09 nm 2012
CH NHIM B MN NGI HNG DN CHNH
(K v ghi r h tn) (K v ghi r h tn)
TS. V CNG HA PGS.TS. TRNG TCH THIN
PHN DNH CHO KHOA, B MN

Ngi duyt (chm s b):
n v:
Ngy bo v:
im tng kt:
Ni lu tr lun n:
LI CM N
Lun vn c hon thnh l kt qu qu trnh hc tp v nghin cu trong nhng

nm hc i hc ca cc sinh vin thc hin. Bn cnh nhng n lc ca sinh vin,
thnh cng ca lun vn khng th thiu s ging dy, quan tm, gip ca tp
th cc thy c gio trng i hc Bch Khoa thnh ph H Ch Minh trong qu
trnh hc tp cng nh lc thc hin lun vn tt nghip ny.
Nhn y, ti xin chn thnh cm n thy hng dn Ts. Trng Tch Thin cng
tp th cc thy c trong b mn c k thut, phng th nghim c hc tn tnh
quan tm, hng dn, truyn t kin thc, kinh nghim, to mi iu kin thun
li gip ti hon thnh tt lun vn ny.
Cng trong dp ny, ti xin chn thnh cm n gia nh v bn b, tp th lp c k

thut h tr chng ti trong sut qu trnh hc tp v thc hin lun vn.
TP.HCM, thng 12 nm 2012

Sinh vin thc hin
Trn Khoa Lut
i
TM TT NI DUNG
Lun vn tp trung nghin cu qu trnh gia cng p lc vi hai bi ton dp su

v ch to co T. hiu r hn qu trnh ny, ban u lun vn tin hnh nghin
cu cc phng php khc nhau gii bi ton bin dng do, bao gm: cc cng
thc gii tch, cng thc thc nghim v phng php phn t hu hn. V nhng
c im ring ca tng phng php nn phng php gii tch v phng php
thc nghim c dng tnh ton cc kch thc c bn ca khun v phi da
vo yu cu ca bi ton, trong khi , phng php phn t hu hn c dng
tin hnh m phng tnh ton nhm kim tra v a ra cc kch thc v qui trnh
hp l hn. M hnh s c to ra v m phng bng chng trnh
ANSYS/LSDYNA sau c kim tra kch thc v h hng vi gin gii
hn gia cng bng chng trnh HyperView v so snh vi kt qu thc nghim.
Ngoi ra, lun vn cn xem xt cc tnh hung thay i kch thc hnh hc, ti tc
dng, hin tng springback.
T kha: L thuyt do, Sheet metal, Deepdrawing, HydroForming, Residual

stress, Tee brand, FEA, LS-DYNA, HyperView, FLDs
ii
MC LC
K HIU ........................................................................................................................ VIII
CHNG 1: TNG QUAN V GIA CNG P LC ................................................. 1
1.1 Gii thiu .................................................................................................................. 1
1.2 Cc qu trnh gia cng p lc ph bin cho kim loi tm ....................................... 3
1.3 Tng quan v khun dp .......................................................................................... 7
CHNG 2: C S L THUYT ............................................................................... 13
2.1 M hnh ng x n trc trong chy do .............................................................. 13
2.2 Quan im Lagrange v quan im Euler v m t chuyn ng .............................16
2.3 Phng php phn t hu hn .............................................................................. 18
2.4 L thuyt tip xc va chm .................................................................................... 29
2.5 Chia li thch ng (Adaptive meshing) ............................................................... 43
CHNG 3: TNH TON V M PHNG BNG PHNG PHP PHN T

HU HN .................................................................................................................... 46
3.1 Tnh ton v m phng bi ton dp su ................................................................ 46
3.2 Phn tch nh hng ca mt s iu kin khc trong qu trnh dp .................. 86
3.3 M phng bi ton to co T bng thy lc ............................................................ 90
CHNG 4: KT LUN V KIN NGH ......................................................... 117
4.1 Kt lun................................................................................................................. 117
4.2 Kin ngh .................................................................................................. 117
TI LIU THAM KHO .............................................................................................. 119
PH LC ...................................................................................................................120
A. Bi ton dp su .................................................................................................... 120
iii
B. Bi ton gia cng co T bng thy lc ................................................................... 130
C. Chng trnh LS-DYNA ...................................................................................... 139
D. Chng trnh HyperView ..................................................................................... 142
iv
DANH MC HNH
v
vi
DANH MC BNG
vii

K HIU
ng sut v bin dng
hoc n ng sut php
hoc t ng sut tip
s hoc o ng sut chy
ng sut tng ng
bin dng php
Cc thng s vt liu
E m un Young
h s Poission
khi lng ring
k h s cng
n h s m bin cng
c vn tc lan truyn m thanh
Cc k hiu khc
{} vec t
[] ma trn
|| || ln vec t
fn lc php tuyn
ft lc tip tuyn
v vn tc trt
x, y, z hoc x1 , x2 , x3 cc ta -cc
h s nhn ca h s ma st
khong chuyn tip gia vng ma st v vng trt
h s ma st
W nng lng
viii
Chng 1: Tng quan
CHNG 1: TNG QUAN V GIA CNG P LC
1.1 Gii thiu
Phng php gia cng p lc l phng php gia cng da vo nguyn l bin
dng do ca kim loi di tc dng ca ngoi lc nhm lm thay i hnh dng,
kch thc ca phi theo mun. Vi cc u im kh c mt s khuyt tt
nh r kh, r co lm t chc kim loi mn, c tnh sn phm cao. bng,
chnh xc cao hn cc chi tit c v d tin hnh c kh, t ng ha nn nng sut
cao v gi thnh h. V c bn, c th phn loi cc phng php gia cng p lc
thnh nhng loi sau
Phng php cn (rolling).
Phng php ko, p kim loi (extrusion, drawing).
Rn t do (forging).
Dp nng, dp ngui (stamping).
Trong iu kin gii hn v thi gian, lun vn ch tp trung vo vn gia
cng p lc cho tm mng m c th l trong qu trnh dp su v qu trnh gia cng
co T bng thy lc. Cng ngh cn lin tc ngy nay to ra cc tm mng c
cht lng cao vi gi thnh thp. Phn ln kim loi tm c to ra bng cch
cn nng hoc ngui, sau chng c a vo s dng trong cc lnh vc sn
xut my mc, cng trnh xy dng, bnh cha ha cht, thc phm v rt nhiu
ng dng tng t khc. So vi cc phng php nh c, ct gtphng php
gia cng p lc cho nng sut cao v gim gi thnh ng k, ngoi ra, cc tnh cht
ca sn phm nh hnh dng, khi lng, dy, bng, tnh thm m c
kim sot tt hn. Cng ngh dp kim loi c nhng bc tin ln khi m
nhng vt liu c mun n hi v mun do cao, do sn phm sau khi c
to hnh c cng, t s gia bn trn khi lng ngy cng ln v c c tnh
GVHD: PGS.TS. Trng Tch Thin 1 SVTH: Trn Khoa Lut

Chng 1: Tng quan
vt tri so vi cc phng php khc nh c, ct gt. Trong iu kin sn xut

hng lot, s dng khun dp cho nng sut cao nht.

Chng 1: Tng quan
1.2 Cc qu trnh gia cng p lc ph bin cho kim loi tm
1.2.1 Qu trnh to phi (blanking and piercing)
Thng thng kim loi tm c bo qun dng cun, qu trnh u tin l

tri phng v ct thnh tng tm nh, nhng tm nh ny c th c a vo
khun dp to hnh hoc ct thnh tng ming nh hn. Tuy khng y cha hn l
qu trnh gia cng p lc nhng vn c kho st do tnh ph bin ca n v hu
ht phi kim loi tm c to thnh theo cch ny. y, sau khi phi c to
thnh, vng ra b bin cng, iu ny s gy ra kh khn trong qu trnh dp tip
theo.
Hnh 1.1: Sn phm sau khi dp ct
1.2.2 Qu trnh un (bending)
Qu trnh un n gin nht l to np gp thng trn tm kim loi. c im

ca qu trnh ny l ch c khu vc b un (nh) chu bin dng, phn cn li th
khng. Nu kim loi khng ng nht hoc c khuyt tt, h hng vn c th xut
hin ngoi vng un, v nh hng ca hin tng n hi (springback) l ng
k.

Chng 1: Tng quan
Hnh 1.2: Qu trnh to gc ln bng phng php un
1.2.3 Qu trnh p dn u (stretching)
y l qu trnh to hnh trong phn ln tm kim loi c ko dn v un

ng thi bng trn khun.Vng bin ca phi c c nh v chy c dng khi
lin p vo phi theo phng ng. ng sut ko xut hin vng bin v ng
sut nn xut hin ti vng tip xc gia e v tm kim loi.
Hnh 1.3: Qu trnh p dn u
1.2.4 Qu trnh to l (hole extrution)
Qu trnh m rng l c sn v to thm vin (flanger) mt pha ca phi.

Chng 1: Tng quan
Hnh 1.4: Kt qu qu trnh to l
1.2.5 Qu trnh dp (stamping, draw die forming)
Qu trnh dp c xem l qu trnh gia cng p lc rng ri nht. N c th

loi b nhiu thnh phn ca mt chi tit m trc y mun lin kt phi dng
mi hn, inh tn. Mc d phng php dp c p dng t rt lu nhng thi
gian v gi thnh cho vic ch to khun vn cn rt tn km do phi lm nhiu
mu th, c bit khi phi ch to nhng chi tit c:
- Bin dng ca chi tit phc tp
- Ma st gia phi v khun bin i lin tc
- Cc qu trnh gin n v nhit, ch dp
- Hin tng n hi (springback) sau khi tho khun
Trong qu trnh dp to hnh, c ba qu trnh c bn:

- Dp su (deep drawing)
- Dp li (redrawing)
- Dp vut (ironing)

Chng 1: Tng quan
Hnh 1.5: Sn phm ca qu trnh dp su.
1.2.6 Qu trnh gia cng thy lc (fluid forming, hydroforming)
Trong qu trnh ny, p lc lu cht thay th cho v tr ca chy trong cc qu

trnh dp thng thng. Trong phng php gia cng thy lc, phi b chy do v
in y ch trng ch yu bng p lc lu cht. u im ca phng php ny
l khun n gin, t chi tit v vy gi thnh r hn so vi vic ch to khun
nhiu phn. Mt u im khc ca phng php ny l to ra nhng sn phm c
hnh dng phc tp nh co X, co T, cc loi ng nhiu mt ct (profile) m khng
phi dng n phng php c nhng vn m bo c c tnh v s ng u
vt liu.Ngoi ra, do s dng lu cht nn trnh c cc hin tng dn n v
nhit, gim thiu ma st, an ton trong vn hnh. Nhc im chnh ca phng
php l i hi p lc cao, kn kht ca khun v thi gian chun b lu hn so
vi cc phng php khc. Vi u im an ton, r tin, to ra c nhng bin
dng phc tp m khng cn phi hn nhiu chi tit phng php gia cng bng
thy lc ngy cng c p dng rng ri, c bit trong lnh vc ng ng v
cng nghip t.

Chng 1: Tng quan
Hnh1.6: Co THnh
c1.6:
snCo T c
xut bng sn xut php
phng bng thy
phng
lc php thy lc
1.3 Tng quan v khun dp
Khun dp trc y c ch to theo kiu th sai nn phi lm v chnh

sa rt nhiu, hn na ta cng khng bit ch gia cng hp l nn khi phng
php s ra i gip d on v ci thin ng k s mu th cng nh a ra ch
gia cng hp l, lm gim chi ph ch to ng thi nng cao cht lng sn
phm.
1.3.1 Phn loi khun dp
Ty theo cu to hay cch thc lm vic m ngi ta phn loi cc khun khc
nhau, trong khun kh ca Lun Vn ch trnh by hai loi khun dp thng c
s dng:

Chng 1: Tng quan
khun phc hp (Compound dies)
Hnh 1.7: Khun phc hp
Khun phc hp bao gm cc b phn c ch to vi yu cu cao v chnh

xc, tc lm vic so mc trung bnh. Khun ny c mt phn c nh v
cc phn khc c lp vi nhau thc hin nhiu nhim v nh dp ni, ct, to
l kiu khun ny, khng c s kt hp lin tc ca cc qu trnh lin tip
to ra sn phm hon chnh.
Mt bin th ca khun phc hp l khun kt hp (combination dies): c im
ni bt ca khun ny l c th gia cng phi lin tip m khng phi tho khun,
in hnh ca khun loi ny l khun tandem.
Hnh 1.8: Khun tandem

Chng 1: Tng quan
Khun qu trnh (Progressive dies):
Hnh 1.9: Khun qu trnh
y l loi khun kt hp nhiu khun ring bit v vi nhiu khun con

khc nhau nm chung vo mt . Nhng khun con ny c b tr sao cho c
th tin hnh gia cng c nhiu thao tc lin tip v to thnh mt qu trnh duy
nht.
1.3.2 Cc b phn chnh ca khun dp
Mt khun dp t trng gm cc thnh phn c bn sau:

di (lower shoe, die shoe) v trn (upper shoe). Hai b phn ny
chuyn ng tnh tin vi nhau bng thanh trt (guide pins, guide posts).
C hai kiu chnh:
- Kiu m (open die set) thng c s dng to phi ban u

hoc cc chi tit c cht lng thp, dung sai c b qua. V khng
c thanh dn (guide post) nn chnh xc khng cao.

Chng 1: Tng quan
Hnh 1.10: Khun m
- Kiu c thanh dn (Pillar die set) c s dng ch to cc chi tit

cn chnh xc cao, y cc thanh dn c t ti nhiu v tr
trn khun, m bo chnh xc mong mun.
Hnh 1.11: Khun c thanh dn
trn c gn vo b phn truyn lc nh pit-tng, thanh truyn, d

di c gn c nh vo mt b khun (die block). B ny cn
cha cc chi tit khc nh l xo, cng tc hnh trnhv thng c lm
bng thp cng c. Tng t vi b khun, ta c b chy (punch

Chng 1: Tng quan
plate) c gn pha trn trn, n cha cc chi tit nh chy, l xo v

nhn lc trc tip t pit-tng hay thanh truyn. Gia b chy v chy
thng c lt mt tm mng (back-up plate) nhm ngn nga hin
tng chy ln vo khun.
Ngoi ra cn c cc chi tit khc nh ng dn cht bi trn, cht lm mt,

b phn ly sn phm, khi iu khin (khun modular)
Hnh 1.12: Cu to khun dp hon chnh
- Shank thanh truyn
- Upper die shoe trn
- Spring-loaded knock out/push pin cht l xo gim chn v y phi
- Forming and blanking punch chy to ct phi v to hnh
- Forming support khun trong
- Back-up plate tm lt
- Lower die shoe di

Chng 1: Tng quan
- Back up plate tm lt
- Station stripper b phn chuyn phi

Chng 2: C s l thuyt
CHNG 2: C S L THUYT
2.1 M hnh ng x n trc trong chy do
2.1.1 M hnh n do l tng
Trong mt vi trng hp, khi ta khng tnh n vic bin cng ca vt liu,
m hnh n do l tng c p dng. Mi quan h ng sut bin dng c th
c biu din khi ng sut trong vt th t n ng sut chy s

o
E 2.1

o
E
Hnh 2.13: M hnh n do l tng
2.1.2 M hnh n hi-bin cng tuyn tnh
m hnh ny, ng cong lin tc c xp x bi hai ng thng trong ,

on u tin (1) biu din giai on n hi, on th hai (2) biu din giai on
chy do.

Chng 2: C s l thuyt

o
E
1 2.2
o o
E Et
Hnh 2.14: M hnh bin cng tuyn tnh
2.1.3 M hnh n hi-bin cng hm s m
Quan h ng sut bin dng c cho bi:
k n 2.3

Chng 2: C s l thuyt
Hnh 2.15: M hnh n hi bin cng hm s m
Trong , k v n l hai hng s t trng cho vt liu, chng c xc nh sao
cho ph hp tt nht vi ng cong thc nghim

Chng 2: C s l thuyt
2.2 Quan im Lagrange v quan im Euler v m t chuyn ng
Ti mt thi im t, mt th tch V v bin S ca n xc nh mt min R trong

khng gian. Tp hp v tr tt c cc cht im (particles) cha trong R xc nh
cu hnh ca mi trng .
Khi mi trng lin tc b bin dng (hoc chy), cc phn t ca n di

chuyn lin tc theo nhng l trnh trong khng gian. Nhng chuyn ng ny c
m t theo hai quan im:
2.2.1 Quan im Lagrange
Chuyn ng ca cht im (particle) c m t bng phng trnh c dng
xi xi X1 , X 2 , X 3 , t xi X , t hay x x X , t ( 2.0)
iu ny ng nu cho trc v tr ca cht im xi l X1 , X 2 , X 3 ti thi

im t 0 n m t s thay i cu hnh t trng thi ban u n trng thi hin
ti vi gi nh rng quan h trn l mt-mt v lin tc n vi phn vi bc cn
thit. Ni cch khc, quan im Lagrange l quan st tng ht trong mi trng t
lc bt u n lc kho st.
2.2.2 Quan im Euler
Nu chuyn ng hay bin dng c cho dng sau:

Chng 2: C s l thuyt
X i X i x1, x2 , x3 , t X i x, t hay X X x, t ( 2.0)
trong cc bin s ta v thi gian xi , t l c lp vi nhau ta c php m t

Euler. Cch m t ny cho bit v tr ca cht im ban u nu by gi n
chim v tr x1, x2 , x3 .

Chng 2: C s l thuyt
2.3 Phng php phn t hu hn
2.3.1 Gii thiu phng php phn t hu hn
Trong ton hc cng nh trong k thut, vic tm gi tr chnh xc ca mt hm

trong mt min cho trc thng khng d dng, thay vo ngi ta tm cch xp
x gi tr trong min xc nh ca n. Tuy nhin, hm xp x khng c xc inh
trn ton min xc nh m ch trong nhng khu vc nh hn. V vy, phng php
phn t hu hn rt ph hp cho nhng bi ton trong gm nhiu phn c c
im v hnh hc, vt liu rt khc nhau.
Phng php phn t hu hn ban u c s dng nhng bi ton phc tp

trong min n hi ca cc bi ton kt cu v hng khng. S pht trin ca n bt
u bng cng trnh ca Alexander Hrennikoff (1941) v Richard Courant (1942).
Mc d cch tip cn c khc nhau nhng h u dng chung mt tng l:
chia li vng khng gian lin tc thnh cc min nh hn gi l phn t. Nm
1947, Olgierd Zienkiewicz tp hp cc phng php, xy dng cc biu thc ton
hc. S ng gp ca Courant l pht trin, thu ht mt s ngi nhanh chng a
ra kt qu cho phng php vi phn ton phn c pht trin bi Rayleigh, Ritz
v Galerkin. S pht trin chnh thc ca phng php phn t hu hn bt u
cui nhng nm 1950 trong vic phn tch cc kt cu khung my bay v cng trnh
dn dng mang li nhiu kt qu. Nm 1973, vi vic xut bn cun STRANG
v tng kt trong An Analysis of The Finite Element Method phng php phn t
hu hn c tng qut ha thnh mt ngnh ton ng dng, mt m hnh s hc
cho cc h thng t nhin, c ng dng rng ri trong k thut.
tng ca phng php l chia min thnh nhiu min con r gi l phn
t. Cc phn t ny lin kt vi nhau ti nt trn bin phn t. Trong mi phn t,
i lng cn xc nh c tnh gn ng qua hm xp x (approximation

Chng 2: C s l thuyt
function). Cc gi tr ny khi tnh ti nt s c gi l bc t do ca nt. Cc v tr

khc trong min xc nh khng phi l nt c xp x bng php ni suy.
Hin nay phng php phn t hu hn i theo ba m hnh:
M hnh tng thch: Trong m hnh tng thch, bc t do l chuyn v, cc

n s c xc nh t h phng trnh thit lp trn c s nguyn l th
nng ton phn hay bin phn.
M hnh cn bng: Trong m hnh ny, ng sut hay ni lc l i lng

c u tin tnh trc. Cc n s c xc nh trn c s nguyn l nng
lng ton phn hay nguyn l Castigliano.
M hnh hn hp: Coi cc i lng chuyn v, ng sut l 2 yu t c

lp. Cc hm xp x biu din gn ng dng phn b ca c chuyn v
ln ng sut trong phn t. Cc n s c xc nh t h phng trnh
thit lp trn c s nguyn l bin phn Reisner. Sau khi tm c cc n s
bng vic gii mt h phng trnh i s va nhn c th cng c
ngha l ta tm c cc xp x biu din i lng cn tm trong tt c cc
phn t. V t cng tm c cc i lng cn li.
Trong ba m hnh trn, m hnh tng thch c s dng rng ri hn c.
2.3.2 Trnh t gii bi ton theo phng php phn t hu hn
Bc 1: Ri rc ha min kho st:
Trong bc ny, min kho st c chia lm cc min con e c dng

hnh hc v vt liu thch hp.
Vi mi bi ton c th, ty thuc vo cch m hnh bi ton vi cc ch

sau:

Chng 2: C s l thuyt
- Mc yu cu k thut ca bi ton: S i hi ca cc ngnh k

thut khc nhau da trn nhng tiu chun khc nhau. Trong nhiu
trng hp s cn c s nh gi ph hy, cc ti trng ng phc
tp.
- Dng hnh hc v chi tit: Trong mt m hnh c sn, cc chi tit no

c th c b qua chng hn nh cc mi hn, gc lnMt s
trng hp c h khng lin tc nh s thay i cong ca v, cc
khp ni. nhng trng hp nh th ny, kinh nghim t cc thit
k trc l rt quan trng.
- La chn kiu phn t v chn li: Ty thuc vo cch nhn nhn

bi thc t m phn t c nhng la chn gia phn t khi hay mt
hay phn t bc thp vi bc cao v kiu phn t t gic vi tam gic
(bi ton hai chiu), t din vi lc din (bi ton ba chiu).
- M hnh ti v iu kin bin: V phng php phn t hu hn l

tng ha cu trc thc t nn i khi vic m hnh v p t ti gp
kh khn v ti v iu kin bin phi th hin c cu trc thc.
Phi ngn chn c s khng hi t hoc bt thng trong qu trnh gii.
Bc 2: chn hm xp x thch hp:
V i lng cn tm l cha bit, ta gi thit dng hm xp x ca n sao

cho n gin vi tnh ton nhng vn tha mn cc tiu chun hi t. Dng
hay gp l a thc hoc hm lng gic v tnh kh vi ca hm xp x v vi
phn ca n lun c m bo, ta biu din hm xp x theo tp hp gi tr
(c th l o hm ca n) ti cc nt phn t {q}e .
Bc 3: xy dng phng trnh phn t:

Chng 2: C s l thuyt
bc ny ma trn cng K v
e vec t ti phn t P c
e thit lp
trc tip hoc da trn cc nguyn l bin phn.

Kt qu ta thu c mt phng trnh vit cho phn t c dng:

K e q e P e ( 2.0)
Bc 4: ghp ni cc phn t trn c s m hnh tng thch ta thu c h:
K q P ( 2.0)
Trong : K l ma trn cng tng th
q l vec t chuyn v nt tng th
P l vec t ti tng th

Sau khi p dng iu kin bin bi ton, ta thu c h phng trnh:

K * q * P * ( 2.0)

Bc 5: gii h phng trnh i s:

K * q * P * ( 2.0)
Vi bi ton tuyn tnh, vic gii h phng trnh ny khng kh khn. Kt qu

tm c l chuyn v ti cc nt.
Vi bi ton phi tuyn, nghim thu c sau mt chui cc php lp m trong
ma trn cng K trong bi ton phi tuyn vt l hay vec t ti P trong bi ton
phi tuyn hnh hc c cp nht lin tc.

Chng 2: C s l thuyt
Bc 6: hon thin bi ton
T tp hp cc kt qu bc 5, ta tm cc i lng cn li tt c cc phn
t
Bc 7: phn tch nh gi kt qu.
2.3.3 Thut ton Explicit Finite Element
Tch phn Explicit:
Phng php o hm trung tm c s dng, gia tc c xc nh thi gian t

bng biu thc:
a t M
1
F F
ext
t
int
t ( 2.0)
Trong : F l ti bn ngoi v lc th tch

ext
t
F l ti ni v c xc nh bng
t
int

F int BTn d F hg
Fcontact ( 2.0)

Fhg l lc cn do hin tng hourglass, v Fcontact l lc do tip xc
Sau vn tc v chuyn v c tnh bng
vt t / 2 vt t / 2 at tt
( 2.0)
ut t / 2 ut t / 2 vt tt t / 2
Trong :

Chng 2: C s l thuyt
tt t /2 0.5 tt tt t v t t t / 2 0.5 tt tt t ( 2.0)
V vy v tr cc nt so vi v tr ban u xo s l:

xt t xo ut t ( 2.0)
i vi bi ton phi tuyn th:
- Ma trn khi lng tp trung l cn thit cho vic nghch o c d

dng.
- Phng trnh tr nn r rng v c gii mt cch trc tip.
- Khng c s nghch o ma trn cng. Tt c s phi tuyn u c tnh

vo vec t lc ban u.
- Khi lng tnh ton ch yu l vo vec t lc ban u.
- Khng cn kim tra tnh hi t.
- Bc thi gian tnh ton l phi nh.
Tm li, thut ton Explicit c cc cc bc sau:
- Xc nh cc gi tr ng hc ti nt.

- Tnh ton gia tc ti nt da vo phng trnh ng lc hc c bn:

at M
1
F text F intt ( 2.0)
- Tch phn theo thi gian ta c vn tc v chuyn v:

Chng 2: C s l thuyt
vt t / 2 vt t / 2 at tt
( 2.0)
ut t / 2 ut t / 2 vt tt t / 2
- Tnh ton vec t lc ti phn t:
- Tnh lng bin dng d t sut bin dng &
- Tnh gi tr ng sut t phng trnh

t t f t , d ( 2.0)
- Lp rp cc gi tr ni lc Ft int
t vo cc nt
- Thi gian tng ln mt khong t ri tr li bc 1
So snh thut ton Implicit v Explicit:
Thut ton Implicit gii phng trnh

K X F X K F
1
( 2.0)
Nhn xt:

- Trong phng trnh trn, ma trn K c nghch o gii h. Tuy K
l ma trn tha nhng vn tn nhiu ti nguyn my tnh.
- Li gii khng tng minh v phi nghch o ma trn.
- Kt qu bi ton l chuyn v ti nt, cc kt qu v gia tc v vn tc c

c bng php ly o hm chuyn v.
- Phng trnh cha bin lin quan n thi gian l K v X v c gii

bng cch s dng phng php lp Newton-Raphson ti mt thi im.
- Thch hp cho cc bi ton tnh, ta tnh.

Chng 2: C s l thuyt
Thut ton Explicit gii gia tc trong phng trnh:

K x C v M a F ( 2.0)
Nhn xt:
- Gia tc l bin theo thi gian.
- Ma trn M c nghch o gii tuy nhin:
- Khi lng ca h c th quy v khi lng tp trung ti nt.
- Do M l ma trn ng cho chnh nn vic ly gi tr nghch o rt

nhanh chng.
- Vn tc v chuyn v c tnh t gia tc mt cch d dng sau mi bc

tnh.
- Phng trnh khng ph thuc r rng vo thi gian nn c th gii tng

minh.
- Khng cn vng lp cho mi bc thi gian.
- Cn thit lp bc thi gian nh cho thut ton Explicit.
- S dng tt cho cc bi ton ng, bin dng ln, thi gian ngn.
- Phm vi p dng ca cc thut ton:

Chng 2: C s l thuyt
Hnh 2.16: Phm vi p dng thut ton Implicit v Explicit
Hnh 2.17: So snh hai thut ton trong mt m phng ko n trc
a)Kt qu ca thut ton Implicit, Explicit (4 bc) v li gii gii tch

b) Kt qu ca thut ton Explicit (20 bc) so vi li gii gii tch

Chng 2: C s l thuyt
Bng 2.1 u im v nhc im ca hai thut ton
Thut ton Implicit (ANSYS) Thut ton Explicit (LS-DYNA)
- i vi bi ton tuyn tnh, - Cho li gii nhanh trong cng mt

bc thi gian c th ln ty bc thi gian.
.
- S dng t ti nguyn hn.
U - Thch hp cho nhng bi ton

- Cn t d liu trn mt phn t
thi gian tnh ton lu di.
hn.
I
- Khng cn tnh nng lng
M - Khng cn kim tra tnh hi t trn
ban u.
mt bc thi gian.
- Nhiu kiu phn t c p
- S loi phn t t.
dng.
N - chnh xc ca phn t t din

- C th gp kh khn v tnh
H cn c xem xt cn thn.
hi t khi gii bi ton phi
tuyn.
- Bc thi gian rt nh trong sut
C
qu trnh gii.
- Thi gian gii mt vng lp
I
rt lu.
Tm li ta s dng thut ton Explicit trong cc trng hp sau:
- Chuyn v ln, bin dng ln.
- Qu trnh xy ra rt nhanh.
- Vt liu phi tuyn theo thi gian.

Chng 2: C s l thuyt
- Bi ton c nhiu cp tip xc th.
2.3.4 Gii hn thi gian cho mi bc tnh trong phng php Explicit
Xt vt th mt chiu c m hnh bng ba phn t sau:
Hnh 2.18: M hnh lan truyn ng sut qua ba phn t
Bc thi gian nh nht cho tch phn Explicit ph thuc vo tc lan truyn ng
sut trong vt liu hay l vn tc m thanh trong vt liu y v chiu di nh nht
ca hai nt cng thuc mt phn t.
Nh hnh ta c:
lmin l2
t
min
c c
E ( 2.0)
c
1 2
Trong :
- l s Poisson.
- l khi lng ring ca vt liu.
- E l sut Young.

Chng 2: C s l thuyt
- c l vn tc lan truyn m thanh.
Trong cc chng trnh tnh ton, bc thi gian c nhn vi h s an ton

m bo tnh chnh xc. i vi chng trnh LS-DYNA, h s ny mc nh l
0.9.
2.4 L thuyt tip xc va chm
2.4.1 Gii thiu
Trong k thut, c rt nhiu bi ton lin quan n vn tip xc v va chm,

nht l trong cc qu trnh kim tra sn phm v sn xut. Vic gii bi ton tip
xc-va chm tp trung vo vn x l cc b mt chuyn tip gia cc vt hay
cc b mt trt (sliding interfaces). V d, trong vic m phng va chm tip xc
gia cc chi tit, cc chi tit c gii hn bi nhng b mt trt, qua ta c
th thit lp quan h gia cc vt th l tip xc, trt ln nhau hay l tch ri.
Trong qu trnh dp kim loi tm, cc b mt trt cng c dng m hnh cc
b mt gia khun dp v phi. Trong m phng hot ng ca my mc, cc thnh
phn nh ng c, bnh rng, b tn nhitc th tip xc trong sut qu trnh
lm vic v cc b mt tip xc c x l mt cch t ng l cc b mt trt.
B mt y c nh ngha bi cc phn (segments) tam gic hoc t gic. Mt
pha ca b mt c nh ngha l b mt chnh (master side) v pha cn li l
mt ph (slave side). Tng t, ta c nt nm trn b mt chnh l nt chnh (master
node) v nhng nt nm trn b mt ph l nt ph (slave node).
Trong phng php hm pht (penalty) th s phn bit mt chnh, ph cng nh

nt chnh ph l khng cn thit. Tuy nhin, i vi cc phng php cn li iu
ny l rt quan trng. Nhng nt ph th phi b rng buc trt trn mt chnh
sau va chm v vn phi hin din trn b mt chnh cho n khi lc ko gia nt
v b mt tng cao.

Chng 2: C s l thuyt
Ngy nay, tip xc t ng thng c s dng trong cc bi ton m phng

va chm. Trong loi tip xc ny, s bin i ca b mt chnh v ph hon ton
c iu khin trong chng trnh m ngi s dng khng th can thip.
iu kin ch yu trong bi ton tip xc va chm l iu kin chn (condition

of impenetrability), c ngha l iu kin cc b mt ca hai vt ch tip xc
khng c thm vo nhau. Lc ma st s c x l theo hai m hnh: M hnh ma
st Coulomb c in v m hnh kt cu b mt chuyn tip.
C ba phng php x l vn ny bao gm:
- Phng php rng buc ng hc (kinematic constraint method).
- Phng php hm pht (penalty method).
- Phng php phn phi tham s (distribute parameter method).
2.4.2 Cc phng php x l bi ton tip xc-va chm
2.4.2.1 Phng php rng buc ng hc
phng php ny, rng buc c p t ln phng trnh tng qut bng
cch bin i cc thnh phn chuyn v ca ph thuc vo b mt tip xc. S
bin i ny c tc dng kh bc t do theo phng php tuyn. nng cao hiu
sut tch phn Explicit, khi lng c quy v theo bc t do ton cc ca cc nt
ch ca cp i. iu kin va chm v tch ri c m bo bng cch p t
sao cho m men bo ton. Trong th iu kin tch ri t quan trng hn so vi
iu kin va chm.
Tuy nhin, vn rc ri c th ny sinh vi phng php ny nu b mt

chnh tr nn tt hn b mt ph. y, mt s nt chnh c th xm nhp vo
b mt ph m khng gy ra bt k phn lc lin kt no v to ra s xon khi hai

Chng 2: C s l thuyt
b mt trt ln nhau. khc phc iu ny, vic chia li c mn thch hp

cho tng b mt ng vai tr rt quan trng.
2.4.2.2 Phng php phn phi tham s
Trong phng php phn phi tham s, mt na khi lng ca phn t ph

ca mi phn t trong va chm tip xc c phn b n din tch b mt chnh.
Cng vi , ng sut bn trong ca mi phn t xc nh mt s phn b p sut
cho din tch b mt chnh m nhn khi lng phn b trn. Sau khi hon thnh
qu trnh phn b khi lng v p sut, chng ta c th cp nht gia tc ca b
mt chnh. Sau rng buc c p t ln gia tc v vn tc ca nt ph thuc
bo m nt ph thuc phi di chuyn trn mt chnh. y khng cho php s
xm nhp ca phn t ph vo b mt chnh.
2.4.2.3 Phng php hm pht
Trong phng php ny, gia tt c cc nt xm nhp v b mt chung c

t nhng l xo gi lp. Vi vic loi tr s kt hp ma trn cng ca l xo
vi matrn cng tng th th php tch phn Explicit v Implicit l nh nhau. So
vi cc phng php khc th trong phng php ny th m men c bo ton m
khng cn n iu kin va chm v tch ri.
Trong l thuyt phng php hm pht gm c 3 loi nh sau:
- Phng php hm pht chun (standard penalty formulation).
- Phng php hm pht rng buc mm (soft constraint penalty formulation).
- Phng php hm pht da trn cc on (Segment-based penalty

formulation).

Chng 2: C s l thuyt
2.4.2.4 Phng php hm pht chun
Khi p dng phng hm pht chun gii bi ton tip xc-va chm, cc nt
ph s c kim tra thm vo b mt chnh. Nu cc nt ny khng thm th
khng c chuyn g xy ra c, nhng nu chng thm vo b mt chnh th ngay ti
nhng nt ny xut hin mt lc. ln ca lc ny t l vi su thm vo ca
cc nt ph. thm ca nt ph ns qua mt on ca b mt tip xc cha im

tip xc s c ch r nu
t r c ,c 0
l ni ( 2.0)
Trong , ni ni c ,c l php tuyn ca mt chnh ti im tip xc.
Nu im ph ns thm qua mt on si trn b mt chnh th ta s thm vo mt
vect lc lin kt fs
fs lkini nu l 0 ( 2.0)
H s cng ki ca on si trn b mt chnh c cho trong mi quan h vi
m un n hi khi Ki , th tchVi , v din tch b mt Ai ca phn t cha on si
. C th l:
i vi phn t khi lp phng th
f K A2
ki si i i ( 2.0)
Vi
i vi phn t tm v th

Chng 2: C s l thuyt
fsi Ki Ai
ki ( 2.0)
max shell diagonal
Vi fsi l h s t l cho cng v thng mc nh l 0.1 .
Vi nhng gi tr ln, xm nhp l nh, bi ton cng chnh xc nhng li d mt

n nh.Vi nhng gi tr nh, xm nhp l ln, bi ton n nh nhng li gim
tnh chnh xc.
2.4.2.5 Phng php hm pht vi rng buc mm
Cc vt liu mm gy ra nh hng khng mong mun i vi h s cng

tip xc, n lm gim cc gi tr cng v cui cng gy ra cc thm qu mc
ca cc nt ph vo b mt chnh. x l vn ny, ta t h s t l ca
cng tip xc l SOFT = 0 , c gi l pht biu hm pht vi rng buc mm.
Mc ch ca vic ny l loi cc thm qu mc.
thm vo cc cng tip xc ca cc b mt chnh v v b mt ph, mt

cng khc c tnh ton da vo n nh ca h cc b gm hai khi lng
c ni vi nhau bi mt l xo. cng c thm vo gi l h s cng n
nh v c tnh nh sau
k t 0.5 SOFSCL 1
m*
( 2.0)
t c t
sc

y:
- SOFSCL l h s t l cho hm pht vi rng buc mm, c

thit lp trong phn *CONTROL_CONTACT ca LS-DYNA.
- m* l hm khi lng ca cc nt ph v cc nt chnh

Chng 2: C s l thuyt
- tcs l bc thi gian ban u gii
2.4.2.6 Phng php hm pht da trn cc on
y l ty chn dnh cho cc phn t Shell v Solid khi dng thut ton tip xc
dng hm pht. Ty chn ny tng t vic s dng h s c cng SOFT =1 ,
nhng v chi tit th c hi khc mt cht.
2

SFS
k t 0.5 SLSFAC m1m2 1
( 2.0)

m m t t
cs
or

1
SFM 2
c
Khi lng ca cc on c s dng thay cho khi lng ca cc nt. Khi

lng cc on bng vi khi lng phn t i vi phn t tm v, v bng mt
na khi lng i vi phn t khi. Ging nh phng php hm pht vi rng
buc mm, tc l bc thi gian ban u gii v s c iu chnh khi qu

ln trnh lm cho bi ton mt tnh n nh. Cc ny khc vi vic s dng h
s cng SOFT 1 cch thc iu chnh bc thi gian ban u tc , tc ch
c iu chnh khi vt qu 5% gi tr ban u.
2.4.2.7 Tnh ton nng lng tip xc
Nng lng tip xc, Wcontact , s tng khi chuyn t bc thi gian n sang n 1
ti mi b mt tip xc
1
nsn nmn n
W 2
F
n
n1
Wcontact Fi slave distislave i master distimaster ( 2.0)
contact

i 1 i1
Vi:
nsn l s nt ph, nmn l s nt chnh.

Fislave l lc lin kt gia cc nt ph th I vi on tip xc.
Chng 2: C s l thuyt
Fimaster l lc lin kt gia nt chnh th I vi on tip xc.
distslave
i l khong cch m nt ph th I dch chuyn trong bc thi gian
hin ti.
distmaster
i l khong cch m nt chnh th I dch chuyn trong bc thi
gian hin ti.
Trong bi ton b qua lc ma st, cc nng lng b mt ph v b mt chnh
c ln gn bng nhng tri du. Nng lng tng, Wcontact s bng vi nng
lng d tr. Cc nng lng d tr ny s c trnh by trong tp tin SLEOUT.
2.4.3 Ma st trong bi ton tip xc-va chm
Ma st l mt hin tng vt l phc tp bao hm nhng tnh cht ca b mt vt

liu nh nhm, nhit , ng sut php, vn tc tng i. Cho n ngy nay,
hin tng ma st vn ang l 1 ch cn nghin cu v pht trin trn th gii.
y xin c trnh by 2 m hnh ma st ph bin l ma st Coulomb v ma st
trt. Trong m hnh ma st Coulomb c p dng ph bin nht trong cc bi
ton k thut nhng trong cc bi ton bin dng khi th ngoi l. Trong bi ton
ny c ma st Coulomb ln ma st trt u c ng dng vo m hnh.
2.4.3.1 M hnh Coulomb

M hnh Coulomb c nh ngha nh sau
t (dnh) ( 2.0)
t n .t (trt) ( 2.0)
Trong :
t : ng sut tip.
: ng sut php.
: h s ma st.

Chng 2: C s l thuyt
t : vector tip tuyn theo phng vn tc.
vr
t , vr l vn tc trt tng i.
vr
Tng t nh vy, ta c cng thc theo lc php tuyn thay v theo ng sut
nh trn
ft fn (dnh) ( 2.0)
ft fn .t (trt) ( 2.0)
Trong :
ft : lc tip tuyn.
fn : lc php tuyn.
Hnh 2.19: M hnh ma st Coulumb
S chuyn tip t hin tng dnh (stick) sang trt (slip) rt kh m xc nh

chnh xc trong tnh ton s. n gin ha ngi ta dng cc dng xp x nh
sau

Chng 2: C s l thuyt
Hnh 2.20: Cc dng xp x ca m hnh ma st Coulumb
2.4.3.2 M hnh arctangent
Bin php u tin l s dng nhng hm kh vi lin tc vi s biu th ca

vn tc trt tng i
ng sut ma st:
2 || vr ||
arctan t ( 2.0)

t

RVCNST
Lc ma st:
f f 2 arctan || vr || t ( 2.0)
n
t
RVCNST
V bn cht vt l th RVCNST c th c xem nh l vn tc trt khi hin

tng trt xy ra. RVCNST rt quan trong trong vic xc nh dng hm xp x
ca mu ma st Coulumb nh hnh. Gi tr RVCNST cng ln th cng lm gim gi
tr ca ma st hiu dng v cng nh th lm kh khn trong kt qu hi t. Gi tr
RVCNST nn nm trong khong t 1% n 10% vn tc trt .

Chng 2: C s l thuyt
Hnh 2.21: S xp x hm bc vi cc gi tr ca RVCNST
2.4.3.3 M hnh Stick-Slip
Bin php th 2 l da trn hm bc ci tin vi dng yu. Dng ny c th

s dng miu t tnh cht dnh v trt ca b mt ma st.
Hnh 2.22: Cc thng s trong m hnh Stick-slip
Trong
: l s nhn ca h s ma st.
: l khong chuy tip gia vng dnh v vng trt.

Chng 2: C s l thuyt
: l h s rt gn ( khong 10-6).
Hnh 2.23: Lc gii ca dng Stick-slip
2.4.3.4 M hnh Bilinear (dng song tuyn tnh)
Gii php th ba ny cng tng t m hnh th 2, cng da trn khong cch

tip xc gia 2 vt .Thay v xc nh nhng lin kt rng buc iu kin dnh,
m hnh Bilinear cho rng iu kin dnh v trt tng ng vi s thun nghch
(n hi) v s c nh (do) .
nh lut ma st Coulomb c biu th di dng b mt trt nh sau
|| ft || fn ( 2.0)
H s vector khong cch tip xc c chia thnh 2 phn n hi v do
u& t u& te u& tp ( 2.0)
H s vector lc ma st th ch lin quan n khong cch tip xc n hi

Chng 2: C s l thuyt
f& Du& e ( 2.0)

t t
Vi D l ma trn i xng
fn
0

D 2.34
fn
0

Hnh 2.24: M hnh song tuyn tnh
Gii hn ca m hnh ma st Coulomb:
Khi lc php tuyn v ng sut tr nn qu ln, m hnh ma st Coulomb khng

th hin kt qu tt vi s th nghim. Nguyn nhn bi m hnh Coulomb d bo
rng ng sut trt tng ti mt mc no c th vt qua ng sut chy v ng
sut ph hy ca vt liu. Nh vy th khng ng vi thc t. Mt m hnh ma st
khc cn c p dng trong trng hp ny. S la chn c ra l c h s
ma st phi tuyn hay gii hn ng sut ma st trong mu tuyn tnh hay s dng
bin dng trt trong ma st.

Chng 2: C s l thuyt
Hnh 2.25: ng x ca m hnh Coulomb tuyn tnh
Hnh 2.26: Gii hn ng sut ma st trong m hnh song tuyn tnh
2.4.3.5 M hnh ma st trt
S ct da trn tnh cht ng sut ma st l mt thnh phn ca ng sut tng

ng ca vt liu.
ng sut tip c nh ngha

| t | m (min dnh) ( 2.0)
3

v t m t ( min trt) ( 2.0)
3
Vi m l h s ma st.

Chng 2: C s l thuyt
Tng t vi m hnh ma st Coulomb, m hnh ma st ct cng s dng 2 dng

xp x:

Kiu arctangent
2 vr
m arctan t ( 2.0)

3
t

RVCNST
Kiu tuyn tnh

min m , m ( 2.0)
n
3
t

2.4.3.6 H s ma st
Khi mt nt tip xc vi vt cng, h s ma st lin kt vi vt cng c s

dng. Khi mt nt tip xc vi vt bin dng, gi tr trung bnh ca cc h s ma
st ca hai vt c s dng. La chn CONTACT TABLE c th c s dng
trong nhng trng hp phc tp.
Ma st l mt hin tng vt l phc tp, theo nhiu bin trong nhng iu

kin nh l b mt, iu kin bi trn, nhit , hnh hcv c chia ra lm hai
loi l ma st trt v ma st Columb. H s ma st l mt hm nh sau:

x, f n ,T , vr , ( 2.0)
x : v tr ti im tnh ma st.
fn : lc php tuyn ti im tnh ma st.
T : nhit ti im tnh ma st.
vr : vn tc trt tng i gia im tnh ma st v b mt.
: ng lng ng sut ti im tnh ma st.

Chng 2: C s l thuyt
2.5 Chia li thch ng (Adaptive meshing)
Trong qu trnh phn tch vt chu bin dng b, li gii theo quan im
Lagrange t gi tr chnh xc cao nhng khi bi ton c s bin dng ln v mt
hnh hc hay vt liu b ph hy phng php tip cn Lagrange khng cn thch
hp na v thay vo l phng php tip cn Euler. Tuy nhin phng php
Euler tn rt nhiu ti nguyn my tnh v phi kim sot thm s bo ton khi
lng v mt s tham s khc nn trong mt chng mc nht nh, ngi ta tm
cch m rng phm vi phng php Lagrange bng cch phn vng v chia li li
(rezoning and remeshing).
i vi chng trnh LS-DYNA, phng php hadaptive c dng cho phn

t tm mng. Trong phng php ny, mt phn t ban u phn chia thnh nhng
phn nh hn nhm to chnh xc cn thit. y l mt iu ht sc c ngha
v ta khng phi chia li ban u tht mn v tit kim rt nhiu thi gian tnh
ton.
Li c chia ban u gi l li m, v nhng phn t ban u, nt ban u

gi l phn t m, nt m. Nhng phn t mi, nhng nt mi c to ra t qu
trnh chia li thch ng gi l phn t con v nt con. Nhng phn t con c
to ra bc 2 gi l phn t sinh ln mt (fisrt-generation elements). Ta nt
con c sinh ra c xc nh bng biu thc
1
x x x ( 2.0)
N I J
2
Vi xN l ta nt con nm trn cnh ca phn t c xc nh bng hai nt
c ta xI , xJ .
i vi nt con c sinh ra gia phn t m, v tr c xc nh bng biu

thc

Chng 2: C s l thuyt
1
x x x x x ( 2.0)
M I J K L
4
Vi xM l ta nt mi sinh, v xI , xJ , xK , xL l ta ca bn nh ca phn
t m.
Nu nt mi sinh trn cnh th vn tc di l
1
v
N
vI vJ ( 2.0)
2
Tng t ta c vn tc gc
1

N
I J ( 2.0)
2
Nu nt mi sinh nm gia phn t m th vn tc di l
1
v v v v v ( 2.0)
M I J K L
4
Tng t ta cng c vn tc gc
1
( 2.0)
N I J K M
4
Bc ca li thch ng c xc nh theo ba quy tc sau
- S bc chia thch ng ca phn t c gii hn bi s bc chia thch ng

cho php ca li, thng l ba hoc bn bc.
- Cc phn t nm k nhau, c bc chia li thch ng khng chnh lch nhau

khng qu mt.
- Bc chia li thch ng phi ph hp vi kh nng b nh ca my tnh.

Chng 2: C s l thuyt
Hnh 2.27: Qu trnh phn chia bc mt ca phn t tam gic
Hnh 2.28: Qu trnh chia bc bn ca phn t t gic

Chng 3: Tnh ton & m phng
CHNG 3: TNH TON V M PHNG BNG PHNG

PHP PHN T HU HN
3.1 Tnh ton v m phng bi ton dp su
Bi ton
Mt cc lm bng nhm 3003-O c cc kch thc nh sau:
h 100mm l chiu cao ca chi tit.
d 160mm l ng knh ngoi ca chi tit.
t0 2mm l chiu dy ban u ca phi cng l chiu dy y sn phm.
tw 1.5mm l chiu dy ti thiu ca thnh sn phm.
3.1.1 nh ngha n v v tham s trong qu trnh m phng
Bng 3.2: n v dng trong m phng
STT i lng n v
1 Chiu di mm
2 Thi gian s
3 Vn tc mm/s
4 Khi lng kg
5 Khi lng ring kg/mm3
6 Lc mmN
7 ng sut mmN/mm2 hay KPa

Bng 3.3: Tham s dng trong m phng
STT i lng K hiu
1 B dy phi thk
2 B dy phn t khun, chy, blankholder, supportplate thk_1
3 B dy mng nht ca thnh sn phm thk_2
4 Bn knh phi rmt
5 Bn knh chy ngoi rp_1
6 Bn knh chy trong rp_2
7 Gc ln chy ngoi rfp_1
8 Gc ln chy trong rfp_2
9 Bn knh khun dp su rd_1
10 Bn knh khun dp li rd_2
11 Bn knh khun dp vut rd_3
12 Gc ln khun dp su rfd_1
13 Gc ln khun dp li rfd_2
14 Khong h gia chy v khun dp su c1
15 Khong h gia chy v khun dp li c2
16 Chiu cao chy hp_1
17 Chiu su khun dp su hd_1
18 Chiu su khun dp li hd_2
19 Chiu su khun dp vut hd_3

3.1.2 Cc bc tnh ton ban u
i vi sn phm gia cng nh qu trnh dp, bin dng t c l rt ln,

ngi ta phi dp nhiu ln. S lng ln dp nhn chung ph thuc vo t l
gia chiu cao v ng knh y sn phm. Ta c th tham kho bng sau:
Bng 3.4: S ln dp ngh cho qu trnh dp su
h 0.6 0.6-1.4 1.4-2.5 2.5-4.0 4.0-7.0 7.0-12.0

nd 1 2 3 4 5 6
h 100
Theo thng s bi ton: 0.625
d 160
V vy ta chn n 2 ln dp, kt hp vi ln dp vut hon thin b mt sn

phm.
Qu trnh dp su
Xem th tch ca phi trc v sau gia cng l khng i ta c
D o2t 0 2dt h d 2t o
w
4 4
8dtw h
D d 2
8 160 2 100 300 mm
o
1602
t0 1.5
Hoc ta dng cc cng thc n gin hn cng cho ra kt qu tng t
D d 2 4dh khi d 20r

D d 2 4dh r khi 10r d 15r 3.1
D d 2 4dh 0.5r khi 15r d 20r
D d 2r 4d h r 2 r d 0.7r
2
khi d 10r
V vi mi ln dp vi bn knh Ri , chiu cao ca phi c tnh bng cng thc

D D
2
H i

o

1 3.2
4 D
i
1 - Chy
2 - Khun
3 khun
4 - Phi
5 Vng iu chnh
Hnh 3.29: Cc kch thc c bn cho ln dp u tin
Theo cng thc E.Kaczmrek bn knh ti gc ln ca khun ti ln dp u tin:
Rp 0.8 D d1 t0 3.3.a
Trong
D l ng knh ca phi
d1 l ng knh trong ca chy
to l b dy ca phi
Tng t ta c cng thc tnh gc ln ti ln dp th hai v tng t cho cc ln

tip theo
R p n 0.8 d1 d n T 3.3.b

Tuy nhin, ta cng c th chn bn knh gc ln s b cho chy v khun nh sau
R p 4 t0 3.3.c
Rd 6 t0 3.3.d
V vy bn knh gc ln ca chy v khun ln lt l:
Rp1 Rp 2 4 2 8 mm
Rd1 Rd 2 6 2 12 mm
T s gii hn gia cng (limited drawing ratio) l t s gia ng knh ln nht
trong mt ln dp so vi ng knh ca chy:
Max
LDR D0 3.4
Dp
T s ny thay i theo tng loi vt liu ca phi v nhn chung, vt liu c
bn cng cao th t s gii hn gia cng cng cao hay l kh nng nhanh chng t
c hnh dng sau mt s t ln gia cng.

Hnh 3.30: Biu t l gii hn gia cng ca mt s vt liu
Vy bn knh ca phi v kch thc d kin sau ln dp u tin
D0 2R0 300mm
LDR 1.333
D1 2R1 200mm
H1 62.5mm
ng knh ca khun ca mi ln dp c xc nh bng cng thc
Dd Dp 2c 3.5
Trong , c l khong h gia chy v khun. Theo cng thc ca Oehler khong
h c chn
c tmax k 10t0 3.6.a
Vi:

tmax l b dy ln nht trong sut qu trnh dp v t0 l chiu dy ban u ca
phi.
k l h s vt liu v c ngh nh sau:
k 0.07 khi vt liu l thp.
k 0.04 cho kim loi mu ni chung.
im hn ch ca cng thc ny l phi tri qua thc nghim mi xc nh c

tmax . vn tr nn n gin hn ta dng cng thc ngh sau:
c 1.4 ~ 1.5 to 3.6.b
ng knh ca khun dp u tin: Dd1 Dp1 1.4to 200 1.4 2 202.8 mm
Ta c: Do D1 300mm 202.8mm 97.2mm 5to 15mm nn ta cn c blank-holder

gi phi.

Qu trnh dp li:
Hnh 3.31: Cc kch thc c bn cho ln dp th hai
Cc kch thc d kin sau ln dp th hai
D0 2R0 300mm
D2 2R2 160mm
H2 100.625mm
V ln dp th hai c nh hng n kch thc cui cng ca vt th, nu k

n hin tng Springback, ta thay i kch thc chy D2 trong cc ln m phng
nhm t c kch thc chnh xc sau khi tho khun.
ng knh khun:
Dd 2 Dp 2 1.4 to 1.4 2 162.8 mm .

160

Qu trnh dp vut (Ironing):
Hnh 3.32: Qu trnh dp vut
Trong qu trnh dp vut, chiu dy ca thnh sn phm c th gim ti 50% ,

tuy nhin gim kh nng hng sn phm, lng gim qua mi ln dp vut
khng nn vt qu 40% b dy thnh sn phm.
Hnh 3.33: Cc thng s ti khu vc bin dng
a) thng s hnh hc ti khu vc bin dng.

b) lc tc ng ln khu vc bin dng trong qu trnh ironing

Cng thc xc nh chiu dy b gim xung trong qu trnh ironing:
tmax 3.7
t2
p d
1 tan
Trong , p , d ln lt l h s ma st gia chy vi phi v gia khun vi phi.

l gc nghing ca mp khun. T biu thc trn, ta thy mun gim b dy trong
qu trnh dp vut th p d v tc l b mt chy c php nhm hn so vi b

mt thnh khun.
3.1.3 M hnh cc chi tit trong qu trnh dp
V bi ton l i xng, ta ly mt phn t m hnh phn tch.
M hnh khun dp
Trong bi tnh ny, do khun dp c lm bng thp hp kim chu va p v

mi mn rt cng so vi phi lm bng nhm nn ta b qua bin dng ca khun.
Mt khc, do ch c phn mt trong ca khun tip xc vi phi nn ta c ch m
hnh mt trong ca khun bng phn t tm v (shell) cng tuyt i.
Khai bo phn t tm v trong ANSYS/ANSYS LS-DYNA:
!!!
ET,1,SHELL163
KEYOPT,2,1,12
RMODIF,5,1,5/6,2,thk_1,thk_1,thk_1,thk_1,0
!!!
- La chn KEYOPT,2,1,12 ngha l dng phn t tm v Belytschko-Tsay

tch phn y (Fully integrated Belytschko-Tsay shell). Vi la chn ny,

b dy ca tng phn t s c tnh li sau mi bc lp v c tnh n s

cong xon ca phn t m mt s KEYOPT khc b qua. Ngoi ra, ngi
dng khng cn phi kim sot hin tng HOURGLASSING, tuy nhin thi
gian tnh ton li tn gp 2.5 ln so KEYOPT,2,1,2.
- RMODIF,2,1,5/6,2,thk_1,thk_1,thk_1,thk_1,0: gn b dy nh nhau ti bn
nt ca phn t tm.
Khai bo thng s vt liu:

EDMP,RIGI,5,7,7
MP,DENS,5,8750e-9
MP,EX,5,2.1e5
MP,NUXY,5,0.3
- Tuy vt liu lm khun c xem khng b bin dng nhng ta vn phi

khai bo m un n hi, khi lng ring v h s Poission.
- EDMP,RIGI,5,7,7 lm tt c cc chuyn v ca khun bng 0.

a b
c d
Hnh 3.34: M hnh tng quan khun v tng thnh phn
a) M hnh khun. b) M hnh khun dp su

c) M hnh khun dp li. d) M hnh khun dp vut.
Hnh 3.35: M hnh khun sau khi chia li
Bng s liu m hnh khun:

Bng 3.5: M hnh phn t hu hn cc thnh phn ca khun
Deep drawing Redrawing Ironing Total
M hnh
Loi phn t Shell 163 Shell 163 Shell 163 Shell 163
S nt 247 323 255 825
S phn t 216 288 224 728
M hnh vt Rn tuyt i Rn tuyt i Rn tuyt i

liu

M hnh hnh hc ca chy trong v chy ngoi
Trong thc t hai qu trnh ny thuc mt hoc khun khc nhau l

my. Nhng trong m hnh ny, ta xt khun dp kiu thnh phn. Chy trong
thc t l mt khi lin tc, vi l lun nh phn khun, ta m hnh chy
gm hai phn chy trong (Punch 1) v chy ngoi (Punch 2). Trong giai on
dp su, c hai chy tham gia hot ng, trong giai on dp li v dp vut
ch c chy trong lm vic.
Cng vi l lun nh phn khun dp, ta m hnh chy bng vt liu cng
tuyt i v s dng phn t tm v.
a c
Hnh 3.36: M hnh tng quan chy v cc thnh phn
a) M hnh chy. b) M hnh chy ngoi. c) M hnh chy trong.

Hnh 3.37: M hnh chy v cc thnh phn sau khi chia li
Bng 3.6: Bng s liu m hnh chy
Chy trong Chy ngoi
M hnh
Loi phn t Shell 163 Shell 163
S nt 306 219
S phn t 276 224
M hnh vt liu Rn tuyt i Rn tuyt i
M hnh hnh hc ca blankholder v support plate

gi cho phi khng b nhn trong qu trnh dp, ta dng blankholder.

Thng thng, khi t s ng knh phi so vi ng knh dp su bng nm
ln chiu dy phi, ta cn dng n blankholder.
Trong qu trnh dp, trnh cho phn phi nm di ca chy b bin dng
qu nhiu, ngi ta thng dng p lc ca kh nn p cht phi vo chy.
Tuy nhin phng php ny phc tp, i hi kn kht cao gia cc chi tit.
Mt phng n khc l dng support plate. Suport plate l mt khi kim loi
nm st pha di phi v c lin kt vi thn khun bng l xo hoc piston
v c chuyn v bng vi chuyn v ca chy trong sut qu trnh gia cng.
Ngoi ra supportplate cn c chc nng y sn phm ra khi khun dp sau khi
gia cng xong.
Hnh 3.38: M hnh phn t hu hn ca blankholder
Hnh 3.39: M hnh phn t hu hn ca support plate
M hnh phi

Hnh 3.40: M hnh phi
Phi c lm bng nhm cn 3003-O c cc thuc tnh c bn sau:
Thnh phn nh sau:
Nhm: 97%-98%.
ng: 0.05-0.2%.
St: 0.7%.
Mng gan: 1-1.5%.
Si-lic: Khng qu 0.6% .
Km: Khng qu 0.1%.
Cc nguyn t khc: Khng qu 0.2%.
Tnh cht:
Nhm 3003-O l hp kim c kh nng chu n mn cao v c bn tt. Qu

trnh ch to n gin khng cn nhit luyn v c kh nng tng bn khi gia cng
ngui. Nhm 3003 rt thch hp cho vic gia cng ngui ln gia cng nng. Ngoi
ra, hp kim ny d tnh khi hn vi cc hp kim nhm khc nh 1100, 6061, 6062.

Chnh v kh nng chng n mn, tnh bn v d gia cng nn hp kim nhm

3003 c dng ch to bn p lc, bnh trao i nhit, thng nhin liu, gng
knh, dng c y t, nh bp.
Bng 3.7: Tnh cht c bn ca nhm 3003-O
Mun n hi E 68948 N mm2
Khi lng ring 2740E 9 kg mm3
H s Poission 0.33
ng sut chy o 24.2297 N mm2
H s phng trnh - k - 205.461 N mm2

- n - 0.268771
ng cong ng sut bin dng ca nhm 3003-O:

M Pa
150
100
50
0 .1 0 .2 0 .3 0.4 0 .5
Hnh 3.41: ng cong ng sut bin dng ca nhm 3003-O

Bng 3.8: S liu m hnh blankholder,support plate v phi
Blankholder Support plate Phi
M hnh
Loi phn t Shell 163 Shell 163 Shell 163
S nt 32 37 387
S phn t 24 27 352
M hnh vt Rn tuyt i Rn tuyt i Vt liu ndo

liu
3.1.4 Mt s loi tip xc c dng trong m phng
Khi m phng qu trnh dp, nh hng qua li gia phi v cc chi tit trong
khun s c nhng yu cu c nhng ng x tip xc ph hp. Mt vi im cn
ch trong vic m phng qu trnh dp
- Vn tc va phi (<6m/s)
- Thi gian ngn (~ 0.2s)
- Bin dng ln, tuy nhin c th d on c mt s v tr tip xc
Trong LSDYNA nh ngha cc kiu tip xc bng sau

Bng 3.9: Cc kiu tip xc trong LS-DYNA
3.1.4.1 Kiu tip xc mt chiu Forming one way surface-to-surface contact
Loi tip xc ny dng c pht trin t kiu tip xc Automatic contact

surface to surface nn t ra rt mnh trong vic xc nh tip xc gia phi v cc
chi tit cn li. Kiu tip xc ny c dng rt ph bin trong vic m phng gia
cng kim loi, y, khun c m hnh rn tuyt i.
3.1.4.2 Kiu t tip xc Automatic single surface contact
Trong hu ht cc trng hp, s tip xc ch xy ra ti v tr phi vi khun,

phi vi chy, phi vi blankholder v phi vi support plate. Tuy nhin, khi phi b
nhn, ta c trng hp t tip xc. Kiu tip xc ny c x l hon ton t ng
v bn ngoi khng th can thip.

3.1.5 Qu trnh m phng
3.1.5.1 Gii thiu
2
8
3
4
7
5
Hnh 3.42: M hnh bi ton
1. Chy ngoi
2. Chy trong
3. support plate
4. Khun dp su
5. Khun dp li
6. Khun dp vut
7. Phi
8. Blankholder

Qu trnh dp c chia lm nm giai on
Giai on chun b
Trong giai on ny, phi c a vo v tr v c c nh bng

blankholder. Lc p trn blankholder c tnh da vo b dy v ng sut ti a
ca phi. Yu cu ca lc p ca blankholder khng c qu yu v s lm cho
phi b nhn, tuy nhin lc p ny cng khng c qu mnh dn n lc ma st
tng cao lm phi b kt. Trong m phng, chy c t st vi phi tit kim
thi gian tnh ton. Lc cn thit p vo blankholder c tnh bi
F 2 k r thk uts 3.6
Vi k 0.3 0.4 l h s t l.
r l bn knh phi.
thk l chiu dy phi.
uts ng sut cc i ca vt liu.
Giai on dp su:
Trong giai on ny, c hai chy v support plate cng dch chuyn xung mt
lng gn bng vi chiu su ca khun dp su. Lc ny phi s b p v trt
dc theo thnh khun. B dy mp phi tng ln, do vy phi c th trt trong
thnh khun d dng, khong h gia chy v khun c xc nh theo cng thc
(3.4). n cui giai on ny, khi phi nm hon ton trong lng khun,
blankholder s ngng di chuyn. Chy ngoi s dng li khi cch y khun dp
su mt khong bng khong cch gia chy ngoi v khun.
Giai on dp li:

Trong giai on ny, chy trong v support plate tip tc di chuyn xung y
ca khun dp li, phi tip tc b p v bin dng ch yu khu vc c bn knh
nm gia chy trong v khun dp su.
Giai on dp vut:
giai on dp vut, ton b thnh sn phm s c nh hnh li b dy.

B dy ca thnh s mng i v tng thm chiu cao, trong khi b dy phn y
sn phm hu nh khng thay i dy.
Giai on tho khun:
Khi hnh trnh ca chy trong v support plate vt qua khun dp vut, lin kt
gia sn phm v thnh khun khng cn, hin tng spring back xut hin v lm
bin dng mt phn sn phm. Lc ny, ta kim tra cc kch thc c bn ca sn
phm: ng knh, chiu cao, b dy ti thiu.
3.1.5.2 Cc iu kin bin v iu kin u

V tnh i xng ca bi ton nn mt phn t m hnh c kho st. V vy ta
t iu kin bin i xng qua cc mt phng Oxy v Oyz. C th hn:
- Cc nt nm trn mt phng Oxy ch c th dch chuyn theo hai phng X

v phng Y
- Tng t cc nt nm trn mt phng Oyz ch c th dch chuyn theo

phng Y v phng Z.
Ngoi ra ta cn rng buc chuyn v ca chy, blankholder, support plate v

khun khi khai bo vt liu, theo :
- Chy, blankholder v support plate ch c th chuyn ng theo phng thng

ng.
- Khun ng yn.
3.1.5.3 Cc ng cong ti
Thi gian m phng
- Thi gian m phng cho qu trnh chun b: 0.01s.
- Thi gian m phng cho qu trnh deepdrawing : 0.04s.
- Thi gian m phng cho qu trnh redrawing: 0.04s.
- Thi gian m phng cho qu trnh ironing: 0.07s.
- Thi gian m phng qu trnh tho khun: 0.04s.
- Tng thi gian m phng: 0.2s.
Hnh 3.43: ng cong ti cho blankholder

Hnh 3.44: ng cong ti cho chy ngoi
Hnh 3.45: ng cong ti cho chy trong v support plate

Ch chia li thch ng
- Chu k kim tra li: 0.015s.
- Gc ln nht gia hai phn t : 5o .
- Chiu di gii hn nh nht ca mt cnh phn t: 2mm.
- Bc chia li: bc 3.
- Thi gian bt u kim tra: 0.03 s.
- Thi gian kt thc vic chia li thch ng: 0.14s.
3.1.5.4 FLDs (forming limit diagrams) biu gii hn gia cng

Trong thc qu trnh gia cng, s rt cn thit nu bit c gii hn khu vc
xy ra s n hi, vt nhn, nt, iu ny s gip tm ra cc bin php thit k cng
nh ti u qui trnh sn xut v nh vy s tit kim rt nhiu thi gian v chi ph.
C nhiu phng php xc nh gin gii hn gia cng. Tuy nhin

phng php n gin nht vn l thc nghim. Mt mu th c nh du trn
trn b mt v tin hnh gia cng. Da vo s bin dng ca cc vng ny m
thng s ch yu l t s bn knh hai trc ln nht sau khi bin dng so vi bn
knh ban u.

Hnh 3.46: Cc trng thi bin dng khc nhau ca mt mu th
T tri sang: khng bin dng, bin dng, ph hy

c im ca gin gii hn gia cng l m t trng thi bin dng phng
do bi ton bin dng tm c xem l bi ton bin dng phng. Trong , bin
dng ln hn c gi l bin dng chnh (major strain) lun lun dng (b ko
dn), bin dng nh (minor strain) c tr s m (b nn) trong trng hp dp su
hoc dng (ko dn) trong trng hp b p dn (strectching).

Hnh 3.47: Cc vng bin dng khc nhau ca mt sn phm
to thnh nhng vng vi cc ng x khc nhau, trn biu FLD ngi ta

nh du cc ng:
1 2 (deep drawing) ko theo hng chnh, nn theo hng ph
1 22 (uniaxial tensile) ko ng tm hay nn mt trc
1 2 (stretch forming) ko dn u.
Cc vng mu trn biu chnh l ch tiu nh gi trong dp vut kim loi

tm. c th hin nh trn hnh sau:

Hnh 3.48: Biu gii hn bin dng v cc vng c trng khc nhau
- ng mu en: ng gii hn gia cng (FLC-Forming limit curve).
- Vng mu xanh l cy: vng an ton.
- Vng mu vng: c nguy c rch hoc ph hy thng ly offset 10% t FLC.
- Vng mu : vt liu b rch.
- Vng mu cam: vt liu qu mng.
- Vng mu xm: vng cha bin dng .
- Vng mu trng: cha bin dng do, c nguy c hi phc (Springback).
- Vng mu xanh da tri: co khuynh hng b nhn.
- Vng mu tm: hon ton b nhn.

Gin gii hn gia cng ph thuc nhiu vo b dy phi t v h s m bin

cng n. Khi tng t v n, ng FLC b y ln cao th hin s tng kh nng gia
cng kim loi.
3.1.6 Kt qu m phng trong tng giai on
3.1.6.1 Kt qu ng sut
Phn b ng sut theo phng bn knh
ng sut theo phng bn knh trong thnh sn phm sau mi giai on phn
b kh ng u v c gi tr nh.
Hnh 3.49: Phn b ng sut theo phng bn knh sau giai on dp su

Hnh 3.50: Phn b ng sut theo phng bn knh sau giai on dp li
Hnh 3.51: Phn b ng sut theo phng bn knh sau khi tho khun

Phn b ng sut theo phng chu vi
Giai on dp u tin gn thnh trn bn trong tn ti ng sut ko ln nht

vi gi tr trong khong 125Mpa ti phn mt na chiu cao phi. Ti mp cc chu
ng sut nn c gi tr -95 Mpa. giai on dp tip, phn b ng sut trn thnh
phi thay i nhiu, ng sut phn b kh u trn thnh phi v vn c gi tr ln
ti khu vc gn mp. Sau khi qua giai on dp vut, ng sut phn b u hn
ti thnh sn phm v phn b ph bin mc 50Mpa.
Max 125MPa
Hnh 3.52: Phn b ng sut theo phng chu vi sau giai on dp su

Max 175MPa
Hnh 3.53: Phn b ng sut theo phng chu vi sau giai on dp li
190MPa
Hnh 3.54: Phn b ng sut theo phng chu vi sau tho khun

Phn b ng sut vonMises
Max 165MPa
Hnh 3.55: Phn b ng sut vonMises ln dp su
Max 190MPa
Hnh 3.56: Phn b ng sut vonMises sau khi dp li

Max 202MPa
Hnh 3.57: Phn b ng sut vonMises sau khi dp vut
3.1.6.2 Kt qu bin dng

Bin dng vonMises sau mi qu trnh
Hnh 3.58: Bin dng vonMises sau qu trnh dp su

Hnh 3.59: Bin dng vonMise sau qu trnh dp li
Hnh 3.60: Bin dng vonMises sau ln dp vut

3.1.6.3 Phn b dy
Hnh 3.61: Kt qu phn b dy sau khi tho khun
3.1.6.4 Kim tra kch thc v h hng khi gia cng

Kch thc ca sn phm sau khi tho khun:

mm
81.7
81.6
81.5
81.4
81.3
81.2
mm
20 40 60 80 1 00
Hnh 3.62: th bn knh lp gia ca thnh sn phm theo chiu cao
mm
2.8
2.6
2.4
2.2
2.0
1.8
mm
20 40 60 80 100
Hnh 3.63: B dy thnh sn phm theo chiu cao
T kt qu v dy v bn knh theo chiu cao, ta thy kch thc ca sn

phm tha mn yu cu bi. Vng vt liu nm di chy hu nh khng thay
i dy, gim nhiu khu vc gc ln v tng dn n mp sn phm. Ngoi
ra, do hin tng Springback, bn knh ca thnh sn phm khi gia cng xong cng
tng dn t y ln mp sn phm.

Hnh 3.64: Phn b ng x ca vt liu sau giai on dp su
Hnh 3.65 Phn b ng x ca vt liu sau giai on dp li

Hnh 3.66: Phn b ng x ca vt liu sau khi tho khun
Nhn xt: da vo biu gii hn gia cng v cc m phng trn ta thy

mi vng ca phi u nm trong gii hn cho php. Hai vng chu nn nm mp
phi v v tr tip xc vi chy, y l khu vc d xut hin cc np nhn, tuy nhin
theo nh cc kt qu v kch thc sau gia cng th iu ny cha xy ra. Cc phn
t nm trong vng an ton cn cch xa vng bin (mu tm) iu ny cho thy cn
kh nng ti u qu trnh dp.

3.2 Phn tch nh hng ca mt s iu kin khc trong qu trnh dp
3.2.1 nh hng ca blankholder
V blankholder ch c tc dng trong giai on dp su nn ta kim tra vai tr

ca n trong giai on ny.
Hnh 3.67: T tri sang: qu trnh dp c blankholder v khng c blankholder
Trong trng hp c blankholder, phi c nh hng nn khng b nhn.

Trong trng hp khng c blankhoder, phi b cong ln v mt n nh sau xut
hin np nhn. Cc np nhn tip tc b bin dng khi dp li v lm hng sn
phm.

3.2.2 nh hng ca support plate
Hnh 3.68: T tri sang: qu trnh dp c support plate v khng c support plate
Trong trng hp c support plate, phi tr nn n nh hn, gim cc hin

tng nhn, bin dng khng mong mun ti y sn phm, qua lm gim t l
h hng v ci thin ng k cht lng sn phm. Khi tc dp l nh, vai tr
ca support plate cha th hin r rng, tuy nhin trong sn xut hng lot, khi tc
dp tng cao, vai tr ca support plate l khng th thiu.

3.2.3 nh hng ca gc ln trn khun
Hnh 3.69: T tri sang: ng sut vonMises ti mt ngoi ca phi tng khi bn knh
gc ln ti khun gim
Nhn xt, khi gc ln qu nh, ng sut sinh ra ti lp ngoi thnh sn phm

ln, d dn n ph hy. Mt khc, khi gc ln qu ln, blankholder b mt tc
dng v nh ni trn, sn phm khi b nhn. V vy, gc ln ca khun
c ngh theo cng thc (3.2) v c th tng gim mt lng nh ph hp
vi cc yu cu thc t.
3.2.4 nh hng ca ma st
Nhn chung, nh hng ca ma st rt phc tp v l mt trong nhng nguyn

nhn chnh gy ra bin dng, h hng b mt sn phm.
Khi tng h s ma st gia khun dp su v blankholder vi phi ri tin hnh

m phng. T gin , ta thy cc phn t trn thnh b ko dn v dn ri vo
vng ph hy. Do h s ma st ca b mt khun vi phi khng c qu cao
dn n hin tng kt phi v nh hng n bng sn phm. Tuy nhin, gi
tr ny cng khng c nh hn h s ma st ca chy i vi phi nh ch ra
cng thc (3.7).

Hnh 3.70: nh hng ca lc ma st
T tri sang: trong iu kin bi trn tt, trong iu kin h s ma st ln.
Hnh 3.71: Gin gii hn gia cng trong iu kin h s ma st tng
Vng mu th hin vt liu b ph hy

3.3 M phng bi ton to co T bng thy lc

Hnh 3.72: M hnh CAD ca h thng
24
R3
100
24
Hnh 3.73: M hnh CAD ca mt na khun, (cc n v theo mm)

Bi ton
Kho st mt phi bng ng c dng ng vi chiu di l 121mm , ng knh
ngoi d0 24mm , v b dy thkm = 1.3mm trong qu trnh p thy lc. Cc tnh cht
vt l gm: sut Young E = 119.860GPa , ng sut chy o = 0.116GPa , s Poisson
6 Kg
= 0.31 v khi lng ring 8.9 10 . Khun c lm bng thp c cc
mm3
6 Kg
tnh cht: sut Young E = 210GPa , khi lng ring 7800 10
mm3
3.3.1 nh ngha n v v tham s trong qu trnh m phng
Bng 3.10: n v dng trong bi ton gia cng bng thy lc
STT i lng n v
1 Chiu di mm
2 Thi gian ms
3 Vn tc mm/ms
4 Khi lng kg
5 Khi lng ring kg/mm3
6 ng sut, p sut GPa
Bng 3.11: Tham s dng trong bi ton gia cng bng thy lc
STT i lng K hiu

1 B dy phi thkm
2 B dy phn t khun, pit tng, supportplate thk_1
3 Chiu di phi l0
4 Bn knh phi rmt

5 Bn knh khun rd
6 Bn knh chy rp_1, rp_2
8 Bn knh cong rfill

3.3.2 M hnh cc chi tit trong qu trnh gia cng
V bi ton l i xng, ta ly mt phn t m hnh phn tch. Vi lp lun

ging nh bi ton dp su, y ta cng hnh cc chi tit mt cch tng t. Vi
bi ton c ng knh ln, punch counter c thm vo kim sot bin dng.
Cu to ca punch counter gm mt tm chn (support plate) v h thng hm (c
th bng l xo hoc bn du c van iu p) nhm m bo bin dng v b dy
ca sn phm. Tuy nhin trong bi tnh ny, do ng knh phi khng ln nn
punch counter khng c mt trong m hnh.
3.3.2.1 M hnh khun

Khun s dng trong qu trnh gia cng bng thy lc gm hai phn ghp li.
Tuy nhin trong m hnh m phng, ta cho rng khun cng tuyt i nn ch m t
phn tip xc vi phi. V vy phn t tm v SHELL 163 c s dng.

Hnh 3.74: M hnh khun

3.3.2.2 M hnh pt tng

Pt tng thc t l mt khi c, c khoan l gia bm nn lu cht.
Vi lp lun ging nh trn, ta m hnh pt tng bng phn t tm v tuyt i
cng.
Hnh 3.75: M hnh pit tng
Bng s liu m hnh khun v pit tng
Bng 3.12: Thng s m hnh ca khun v pit tng
Loi phn t Shell 163 Shell 163
S nt 552 126
S phn t 475 100
M hnh vt liu Rn tuyt i Rn tuyt i

3.3.2.3 M hnh phi
Hnh 3.76: M hnh phi
Khc vi bi ton dp su, y phi c lm bng hp kim ng. Ngoi vt

liu lm bng hp kim ng, trong thc t ngi ta cn s dng thm cc phi lm
bng hp kim nhm, inox...
Cc thng s c bn ca phi:
- Loi phn t: Shell163.
- S nt: 441.
- S phn t: 400.
M hnh vt liu: m hnh vt liu n hi-bin cng hm s m, vi h s cng

(strength coefficient) k=0.4257GPa v s m bin cng (hardening exponent)
n=0.2562

M Pa
350
300
250
200
150
100
50
0 .1 0 .2 0 .3 0.4 0 .5
Hnh 3.77: ng cong ng sut bin dng vt liu ca phi
3.3.3 Cc loi tip xc c dng trong m phng
Trong hu ht cc trng hp, s tip xc ch xy ra ti v tr gia phi vi

khun v gia phi vi pit tng. Trong trng hp phi b nhn, ta c s t tip xc.
V vy, m hnh s tip xc ny ta dng hai kiu tip xc nh trong bi ton dp
su:
- Forming one way surface-to-surface contact.
- Automatic single surface contact
H s ma st tnh c cho 0.15 gia phi v thnh khun. m bo

chng trnh hot ng ng ta cn loi b s thm nhp ban u do s hn ch
ca s lng phn t.Vi ch khi tho khun, cc lin kt gia phi v cc chi
tit khc b mt i nn ta ch cn xa b tip xc gia phi v khun, support plate.

3.3.4 Qu trnh m phng
Gii thiu
Hnh 3.78: M hnh bi ton
1.Khun
2.Phi
3.Pit tng
Qu trnh gia cng c chia lm ba giai on:
Giai on chun b:
Trong giai on ny, phi c a vo v tr v c c nh bng pt tng.

Mt chuyn v nh t ln pit tng nhm c nh v tr ca phi. p sut do lu
cht pha trong phi bt u tng
Giai on nn:

Trong giai on ny, c pit tng bt u dch chuyn ng thi tng p sut bn
trong ng t n gi tr xc nh. Lc ny, kim loi bt u chy do, in vo
nhnh trng ca khun.
Giai on x:
Sau khi phi t kch thc cn thit, ta gim p. Phi vn tip tc bin
dng do p sut vn cha v gi tr 0. Khi phn trn khun c tho ra. Sn
phm c kim tra cc kch thc c bn: ng knh, chiu cao, b dy ti
thiu.
3.3.5 Cc iu kin bin v iu kin u
V tnh i xng ca bi ton nn mt phn t m hnh c kho st. V vy ta

t iu kin bin i xng qua cc mt phng Oxy v Oyz. C th hn:
- Cc nt nm trn mt phng Oxy ch c th dch chuyn theo hai phng X

v phng Y
- Tng t cc nt nm trn mt phng Oyz ch c th dch chuyn theo

phng Y v phng Z.
Ngoi ra ta cn rng buc chuyn v ca pt tng, support plate v khun khi khai
bo vt liu, theo :
- Pt tng ch c th chuyn ng theo phng ngang (phng X).
- Support plate ch c th chuyn ng theo phng thng ng (phng Y).
- L xo c gn mt u vo support plate v mt u c nh.
- Khun ng yn.

3.3.6 Cc ng cong ti
Thi gian m phng:
- Thi gian m phng cho giai on 1: 1.2ms.
- Tng thi gian m phng: 3.5ms.
Step
Step11 Step
Step2.1
2.1 Step 2.2 Step3
Hnh 3.79: ng cong ti ca p sut v hnh trnh ca pit tng theo thi gian
Hnh 3.80: ng cong ti thc nghim v ti m phng (Pinaki, Ray)
Ch chia li thch ng:
- Chu k kim tra li: 0.5ms
- Gc to bi hai phn t lin k: 5o
- Chiu di gii hn ca mt cnh phn t: 1mm
- Bc chia li: bc 3
- Thi gian bt u kim tra: 0.00 ms
- Thi gian kt thc vic chia li thch ng: 3.5ms
3.3.7 Kt qu m phng
3.3.7.1 Kt qu ng sut
Hnh 3.81: Phn b ng sut vonMises ti thi im p sut nn t gi cc i
Hnh 3.82: Phn b ng sut vonMises sau giai on x
3.3.7.2 Kt qu bin dng
Hnh 3.83: Phn b bin dng vonMises lc p sut nn t gi tr cc i
Hnh 3.84: Phn b bin dng vonMises sau giai on x
3.3.7.3 Kt qu chuyn v v phn b dy
Hnh 3.85: Kt qu chuyn v theo phng Y
Hnh 3.86: Phn b dy ca thnh sn phm
3.3.7.4 ng x ca cc vng vt liu

V qu trnh thi kim loi nhnh khun tng t vi qu trnh dp su giai
on u v p dn u (stretch) giai on sau nn ta c th dng gin gii
hn gia cng kho st kt qu. Trong qu trnh gia cng c hai tc ng tri
chiu: pit- tng gy nn theo phng dc trc v p sut lu cht lm dn n theo
phng bn knh nn s c hai vng ng x khc nhau:
Hnh 3.87: ng x ca cc vng vt liu giai on chun b
Trong giai on chun b, bin dng ban u xut hin v tp trung khu vc
quanh mp phi, ni tip xc v nhn chuyn v ca chy, hu ht cc khu vc khc
ca phi vn cn nm trong gii hn n hi. Khi kt thc giai on chun b, bin
dng do lc ny lan ra khp phi nhng ti khu vc chnh gia nhnh khun,
bin dng do t gi tr nh. iu ny cho thy trong giai on u tin, p sut
cha ng gp nhiu vo vic gy ra bin dng ca phi.
Hnh 3.88: Bin dng do ca phi sau giai on chun b
Hnh 3.89: Phn b ng x sau giai on nn
Hnh 3.90: Phn b ng x sau giai on x
giai on nn, bin dng ngy cng ln, tt c cc vng ca phi u

bin dng do. Vng vt liu quanh nhnh khun bin dng rt ln nhng vn cn
cch xa gii hn 10% offset t ng gii hn gia cng (FLC) v phi vn cn kh
nng bin dng m cha b ph hy.
Kt thc qu trnh, tt c cc phn t chu ko ca phi u nm trong vng an

ton, phn cn li nm trong vng chu nn c khuynh hng b nhn. Tuy nhin
cc theo cc kt qu v kch thc v phn b dy th iu ny vn cha xy ra.
Hnh 3.91: Bin dng do sau khi kt thc qu trnh x
3.3.8 So snh kt qu vi thc nghim
Sau khi tnh ton, m phng, ta so snh cc kt qu vi thc nghim:
Hnh 3.92: ng kho st bin dng L v chiu cao H ca co T
Kt qu cc kch thc c bn:
Bng 3.13: So snh cc kch thc c bn ca co T vi thc nghim
Kt qu Kt qu m phng Kt qu m
thc theo Ray, Pinaky phng theo lun
p sut nn cc i (GPa) 0.0450 0.0375 0.0450
Hnh trnh pit tng (mm) 18.50 18.50 18.50
Chiu cao t c (mm) 12.70 12.29 12.22
Sai s chiu cao so vi thc x 3.23% 3.78%
nghim (%)
So snh kt qu v phn b dy t nh co dc theo mt phng Oxy:
Bng 3.14: Kt qu phn b dy theo v tr (n v mm)
V tr 0 2.5 5 7.5 10 12.5 15 17.5
B dy 1.139 1.154 1.174 1.234 1.285 1.304 1.394 1.748
V tr 20 22.5 25 27.5 30 32.5 35 37.5
B dy 1.84 1.864 1.761 1.71 1.73 1.75 1.77 1.78
Hnh 3.93: Kt qu phn b dy theo v tr ca Pinaki, Ray
Hnh 3.94: th phn b dy theo v tr ca Lun Vn
3.3.9 Phn tch nh hng ca mt s tham s ln sn phm
3.3.9.1 nh hng ca bn knh gc ln n chiu cao sn phm

kho st nh hng ca gc ln n chiu cao sn phm, ta kho bn
knh gc ln tng t nh n ln khi ti p sut v chuyn v ca pit tng khng
i:
Hnh 3.95: nh hng ca gc ln ln n chiu cao sn phm
T tri sang: bn knh gc ln 2mm, bn knh gc ln 5mm
Hnh 3.96: th chiu cao ca co t c theo gc ln
Bng 3.13: Chiu cao ca co t c theo tng gc ln
Bn knh gc ln (mm) 2 3 5 7 9
Chuyn v theo phng Y (mm) 9.87 11.96 12.24 13.1 13.31
Nhn xt: i vi cc gc ln khc nhau chuyn v theo phng chiu cao

ca sn phm tng khi bn knh gc ln tng. Ngoi ra ta c kt qu khc cng cho
thy b dy v ng sut trong phi phn b ng u hn khi bn knh gc ln
tng. V vy khi khng c yu cu c bit v bn knh gc ln, ta nn chn gi tr
ny tng i ln.
3.3.9.2 nh hng ca hnh trnh pit tng n bin dng ca phi

Vn vi m hnh nh trn, ta kho st bin dng trong tnh hung: pit tng di
chuyn trong giai on nn vi di hnh trnh ln.
Hnh 3.97: Np nhn pht trin do hnh trnh pit tng qu ln
Hnh 3.98: Np nhn pht trin gia phi
Hnh 3.99: Hin tng phi tch khi khun
T kt qu m phng ta thy, nu hnh trnh pit tng qu ngn, chiu cao ca

phi khng th t c nh yu cu. Trong trng hp hnh trnh ca phi tng
i di v p sut nn cha hp l, vng kim loi gn nhnh khun b bin dng
nn mnh theo phng X, phi c xu hng mt n nh, tch khun v nhn li
thay v tip tc i ln. V vy, ch nn ca pit tng nh hng rt ln n kh
nng bin dng ca phi.
3.3.9.3 nh hng ca punch counter

i vi bi ton c ng knh phi ln, ngi ta dng thm punch counter. Khi
dng cc ti nh ban u nhng khi ta s dng phi nhm v tng ng knh ln
d0=84mm v b dy phi rmt=3mm , kt qu thu c ch ra: khi khng c punch
counter, phi nhanh chng b bin dng v ph hy. Trong trng hp ny, punch
counter hn ch phi chuyn v theo nhnh khun, lm cho bin dng, ng sut,
b dy phn b ng u hn.
Hnh 3.100: nh hng ca punch counter
T tri sang: trng hp c punch counter,trng hp khng c punch counter
3.3.10 Cc cch m hnh ha bi ton v hng gii khc
Ngoi cch m hnh phi bng phn t tm v, ta cng c th m t phi bng

phn t khi. Tuy phn t khi t ra rt thun tin cho vic kho st s bin i
dy, ng sut v bin dng cc b trn phi cng nh s xut hin v pht trin
cc vt nhn nhng phn t khi i hi s m t b mt v iu kin thm rt
cht ch nh ni chng hai, v vy i hi li chia trn b mt phi rt
mn. Hn na, vic s dng phn t khi lm tng s lng phn t ln mt cch
nhanh chng nn s tn nhiu ti nguyn hn.
Ngoi phng n s dng thut ton Explicit, do tc trong bi ton gia cng
ny khng qu cao nn hon ton c th dng thut ton Implicit gii. Trong
chng trnh ANSYS, ta khai bo cc phn t tip xc TARGE170 v CONTA174
cng vi cc h s tip xc km theo. Tuy nhin s dng thut ton Implicit trong
trng hp ny s tn rt nhiu thi gian v chuyn v ca bi ton rt ln nn thi
gian hi t trong mi bc con (substep) rt lu, mc du theo thng thng,
i vi bi ton gia cng kim loi, thut ton Implicit cho thi gian gii quyt nhanh
hn thut ton Explicit t hng chc n hng trm ln.
Qua cc phn tch trn, ta thy m hnh bi ton ny bng phn t tm v v

dng thut ton Explicit vn l ti u nht.
Hnh 3.101: Bi ton m hnh bng phn t khi
Chng 4: Kt lun
CHNG 4: KT LUN V KIN NGH
4.1 Kt lun
Trong hai bi m phng, ta c th thy c s cn thit ca cc tnh ton m

phng trong sn xut. bi ton u (bi ton dp su), kt qu m phng cho
thy tnh hp l ca cc cng thc thit k kinh nghim. Bng vic gii lp nhiu
trng hp v so snh cc kt qu vi gin gii hn gia cng, ta c th thu gn
min cc tham s hnh hc cng nh ch ti c nhiu kh nng to kt qu tt.
i vi bi ton sau (bi ton gia cng co T bng thy lc) kt qu m phng ph
hp rt tt vi kt qu thc nghim. Nhn chung, i vi bi ton gia cng kim
loi, c bit trong trng hp bi ton khng c cc cng thc kinh nghim ta phi
gii lp nhiu ln mi tm ra thng s hnh hc v cch t ti hp l nn tit kim
c rt nhiu chi ph khi ch to mu th. Mt khc, vi nhng tnh ton s b
ban u, d chnh xc cha cao nhng cng gii hn c ng k khu vc
cc thng s trc khi a vo m phng gip tit kim ng k thi gian tnh ton.
4.2 Kin ngh
Khi m phng hai qu trnh gia cng p lc, kh khn ln nht l cc d liu
thc t v h s ma st, cc ng cong vt liu, cc h s ph thuc tc bin
dng. Nu c y nhng thng s trn, bi m phng s t chnh xc cao
hn.
Nu c iu kin v thi gian, v kinh ph, ta c th to nhiu m hnh khc

nhau, thay i nhiu tham s c c nh gi tng qut hn v qu trnh gia
cng, t ti u ha ng cong ti v kch thc phi. Hn na nu thc hin
c th nghim, cc s liu thu c s gip nh gi m hnh mt cch ton din
hn v gin gii hn gia cng ch c ngha nu phi khng qu mng. Vic m
Chng 4: Kt lun
phng cng c th s dng phng php ALE hoc phng php ht (Material
Point MethodMPM) c th m t tng tc gia lu cht vi phi nhm a
bi ton gn vi thc t, t ta c th xc nh s lan truyn p sut mt cch
ng n v tm ra ch ti hp l hn. Mt s bi tnh bng hai phng php
trn cho thy tnh chnh xc cao, trong iu kin bin dng v chuyn v ln m
khng tn qu nhiu ti nguyn my tnh. Tuy nhin hai phng php ny vn cn
kh mi m, i hi kinh nghim v phi kim sot rt nhiu cc tham s cho ra
kt qu hp l.
TI LIU THAM KH O
[1] Trng Tch Thin. (2007). L thuyt do k thut. Nh xut bn i hc

Quc Gia TP.H Ch Minh.
[2] George E.Mase.(1970). Theory and problems of Continuum Mechanic.
McGraw-Hill.Inc.
[3] Han-Chin Wu.(2005). Continuum Mechanics and Plasticity. Chapman & Hall
Press.
[4] Vukota Boljanovic.(2004). Sheet metal forming processes and die design.
Industrial Press.
[5] S.J. Hu, J.L. Duncan, Z. Marciniak.(1992) Mechanics of Sheet Metal Forming.
Edward Arnold, London.
[6] Ivana Suchy.(2006). Handbook of Die Design 2nd. McGraw-Hill.Inc.
[7] Ray,Pinaki.(2005). Computer aided optimization of tube hydroforming
processes. PhD thesis, Dublin City University.
[8] Nguyn Vn Phi,Trng Tch Thin,Nguyn Tng Long,Nguyn nh
Giang.(2003).Gii bi ton c k thut bng chng trnh ANSYS.Nh xut
bn khoa hc v k thut.
[9] ErdoganMadenci,IbrahimGuven,(2006) The Finite Element Method and
Application in Engineering Using ANSYS.Springer.
[10] ANSYS, Inc. Theory Reference.
[11] ANSYS LS-DYNA User's Guide.
[12] HyperView11 User's Guide.
[13] FEA News For December.(2008).
[14] http://www.dynasupport.com/
PH L C
A. Bi ton dp su
FINISH
/CLEAR,ALL
/PREP7
/TITLE,SHEET METAL
C***, SHEET METAL VER: 10, REV: D C***,
AUTHOR: TRAN KHOA LUAT
/View,,-0.87,1,3
!...................
! UNIT
! mm,kg,s,mmN,KPa
!...................
!...................
! PARA
!...................
thk = 2 ! be day phoi
thk_1 = 0.1 ! be day cua phan tu khuon va chay thk_2
= 1.495 ! be day phan vo sau khi ironing rmt =
150 ! ban kinh phoi
rp_1 = 100 -0.5*thk_1 ! ban kinh chay 1 rp_2 =
80 - 0.5*thk_1 ! ban kinh chay 2 rfp_1 = 4*thk
! goc luon chay 1
rfp_2 = 3*thk ! goc luon chay 2 c1 =
1.4*thk ! khoang ho lan 1 c2 = 1.4*thk
! khoang ho lan 2 c3 = thk_2
rd_1 = rp_1 + thk_1 + c1 ! ban kinh khuon 1
rd_2 = rp_2 + thk_1 + c2 ! ban kinh khuon 2 rd_3 =
rp_2 + c3! ban kinh khuon 3
rfd_1 = 6*thk ! goc luon khuon 1 rfd_2
= 6*thk ! goc luon khuon 2 rfd_3 =
6*thk ! goc luon khuon 3 hp_1 = 120 !
chieu cao chay
hd_1 = 80 ! chieu sau khuon 1 hd_2 =
115 ! chieu sau khuon 2 hd_3 = 50!
chieu sau khuon 3
!...................
! GEO
!...................
k,1,0,0.005,0 !chay 02
k,2,rp_2,0.005,0
k,3,rp_2,hp_1,0 l,1,2
l,2,3
lfillt,1,2,rfp_2
k,6,rp_2,0.005,0 !chay 01
k,7,rp_1,0.005,0
k,8,rp_1,hp_1,0 l,6,7
l,7,8
lfillt,4,5,rfp_1
k,16,rp_1+2*thk,thk,0 ! bank holder
k,17,1.01*rmt,thk,0
l,16,17
k,18,0,-0.5*(thk+thk_1),0 ! sheet metal
k,19,rmt,-0.5*(thk+thk_1),0
l,18,19
ldiv,8,0.5
k,20,1.01*rmt,-(thk+thk_1),0 ! khuon 01
k,21,rd_1,-(thk+thk_1),0
k,22,rd_1+thk_1,-hd_1,0
l,20,21
l,21,22
lfillt,10,11,rfd_1
lesize,all,15
lesize,1,,,8 lesize,3,2
lesize,4,,,2
lesize,5,15 lesize,6,4
lesize,7,20
lesize,8,,,20
lesize,9,,,10
lesize,12,2
k,1000,0,0,0
k,1001,0,10,0 arotat,1,2,3,,,,1000,1001,90,1
arotat,4,5,6,,,,1000,1001,90,1
arotat,7,,,,,,1000,1001,90,1
arotat,8,9,,,,,1000,1001,90,1
arotat,10,11,12,,,,1000,1001,90,1
k,36,0,-(thk+thk_1)-0.005,0 ! support
k,37,rp_2,-(thk+thk_1)-0.005,0
l,36,37
lesize,40,,,4 arotat,40,,,,,,1000,1001,90,1
!...................
! MAT 3003-O
!...................
et,1,163
keyopt,1,1,12
et,2,163
keyopt,2,1,0
R,1 !metal
RMODIF,1,1,5/6,2,thk,thk,thk,thk,0
MP,DENS,1,2.7403E-06 MP,EX,1,6.8948E+07
MP,NUXY,1,0.33
TB,PLAW,1,,,2,
TBDAT,1,2.05461E+05 !k
TBDAT,2,0.268771 !n
TBDAT,3,
TBDAT,4,
TBDAT,5,2.42297E+04 !sy
TBDAT,6,
R,2 !1st punch
EDMP,RIGI,2,6,7 ! only Y
MP,DENS,2,8750E-9
MP,EX,2,2.1E8
MP,NUXY,2,0.33
R,3 !2nd punch ! only Y
*CSET,1,2, 2,3,
MPCOPY, ,2,3
TBCOPY,ALL,2,3
R,4 ! blank ! only Y
RMODIF,4,1,5/6,2,thk_1,thk_1,thk_1,thk_1,0 EDMP,RIGI,4,6,7
MP,DENS,4,8750e-9
MP,EX,4,2.1e8
MP,NUXY,4,0.3
R,5 ! die ! All
EDMP,RIGI,5,7,7
MP,DENS,5,8750e-9
MP,EX,5,2.1e8
MP,NUXY,5,0.3
R,6 !support ! only Y
*CSET,1,2, 2,6,
MPCOPY, ,2,6
TBCOPY,ALL,2,6
RMODIF,6,1,5/6,2,thk_1,thk_1,thk_1,thk_1,0 R,7 ! 2nd
die ! All
*CSET,1,2,5,7,
MPCOPY, ,5,7
TBCOPY,ALL,5,7
RMODIF,7,1,5/6,2,thk_1,thk_1,thk_1,thk_1,0 R,8 ! 3rd
die ! All
*CSET,1,2,5,8,
MPCOPY, ,5,8
TBCOPY,ALL,5,8
!...................
! MESH
!...................
!sheet metal
aatt,1,1,1
lesize,31,,,16
lesize,32,,,16
lesize,8,,,16
lesize,29,,,16
amesh,8,9
!1st punch
lsel,s,,,22,25
lesize,all,,,16
allsel aatt,2,2,2
amesh,4,6
!2nd punch
aatt,3,3,2
lesize,16,,,16
lesize,17,,,16
lesize,18,,,16
amesh,1,3
!Blank holder
lesize,27,,,8
lesize,28,,,8
aatt,4,4,2
amesh,7
!1st die
lesize,36,,,12
lesize,37,,,12
lesize,38,,,12
lesize,39,,,12
aatt,5,5,1
amesh,10,12
! Support Plate
aatt,6,6,2
lesize,40,,,6
lesize,41,,,6
lesize,42,,,6
amesh,13
!2nd die k,43,1.01*rd_1,-
hd_1,0 k,44,rd_2,-hd_1,0
k,45,rd_2,-(hd_1+hd_2),0
l,43,44
l,44,45
lfillt,43,44,rfd_1
lesize,43,15
lesize,44,15
lesize,45,2
arotat,43,44,45,,,,1000,1001,90,1
lesize,49,,,16
lesize,50,,,16
lesize,51,,,16
lesize,52,,,16
aatt,7,7,1
amesh,14,17
! iron die
k,48,rd_2,-(hd_1+hd_2),0
k,49,rd_2,-(hd_1+hd_2+2),0
k,50,rd_3,-(hd_1+hd_2+12),0
k,51,rd_3,-(hd_1+hd_2+25),0
k,52,rd_2,-(hd_1+hd_2+30),0
k,53,rd_2,-(hd_1+hd_2+35),0
l,48,49
l,49,50
l,50,51
l,51,52
l,52,53
lesize,53,,,1
lesize,54,2
lesize,55,4
lesize,56,,,1
lesize,57,4
arotat,53,54,55,56,57,,1000,1001,90,1
lsel,s,,,63,68,1
lesize,all,,,16
allsel aatt,8,8,1,0
amesh,17,21,1
!...................
! PART & CONTACT
!...................
EDPART,CREATE EDCGEN,ASSC
EDCGEN,FOSS,1,2,0.2,0,0,0,0,,,,,0,0.08,0,0
EDCGEN,FOSS,1,3,0.4,0,0,0,0,,,,,0,10,0,0
EDCGEN,FOSS,1,4,0.1,0,0,0,0,,,,,0,0.05,0,0
EDCGEN,FOSS,1,5,0.1,0,0,0,0,,,,,0,0.1,0,0
EDCGEN,FOSS,1,6,0.1,0,0,0,0,,,,,0.0,10,0,0
EDCGEN,FOSS,1,7,0.1,0,0,0,0,,,,,0.04,10,0,0
EDCGEN,FOSS,1,8,0.05,0,0,0,0,,,,,0.1,10,0,0
!...................
! LOAD
!...................
save
/prep7
*Dim,time,array,6,1,1,,,,
*Dim,p_1,array,6,1,1,,,,
*Dim,p_2,array,6,1,1,,,,
*Dim,blank_force,array,6,1,1,,,,
*Dim,punch_force,array,6,1,1,,,,
*set,time(1,1,1),0
*set,time(2,1,1),0.01
*set,time(3,1,1),0.05
*set,time(4,1,1),0.1
*set,time(5,1,1),0.16
*set,time(6,1,1),0.2
*set,p_1(1,1,1),0
*set,p_1(2,1,1),0
*set,p_1(3,1,1),-hd_1+c1
*set,p_1(4,1,1),-hd_1+c1
*set,p_1(5,1,1),-hd_1+c1
*set,p_1(6,1,1),-hd_1+c1
*set,p_2(1,1,1),0
*set,p_2(2,1,1),0
*set,p_2(3,1,1),-hd_1+c1
*set,p_2(4,1,1),-(hd_1+hd_2)
*set,p_2(5,1,1),-(hd_1+hd_2+100)
*set,p_2(6,1,1),-(hd_1+hd_2+100+50)
*set,blank_force(1,1,1),-55450000/4
*set,blank_force(2,1,1),-55450000/4
*set,blank_force(3,1,1),-55450000/4
*set,blank_force(4,1,1),-55450000/4
*set,blank_force(5,1,1),-55450000/4
*set,blank_force(6,1,1),-55450000/4
edload,add,rbuy,,2,time,p_1,,,,, !chay 1
edload,add,rbuy,,3,time,p_2,,,,,1 !chay 2
edload,add,rbuy,,6,time,p_2,,,,,1 ! chay 3
edload,add,rbfy,,4,time,blank_force,,,,0,0.04
edload,add,rbfy,,2,time,punch_force,,,,0.05,0.1
asel,s,,,8,9
nsla,s,1
nsel,r,loc,x,0
dsym,symm,x
allsel
asel,s,,,8,9
nsla,s,1
nsel,r,loc,z,0
dsym,symm,z
allsel
!...................
! SOLVE
!...................
/solu EDMP,HGLS,1,4,0.1,1.5,0.06,,,
TIME,0.2,
EDOPT,add,,LSDYNA
EDADAPT,1,on EDADAPT,4,off
EDADAPT,5,off EDADAPT,6,off
EDADAPT,7,off EDADAPT,8,off
EDCADAPT,0.015,5,1,3,0.03,0.12,,2,,,,,
/SOLU EDWRITE,LSDYNA,'file','k',' '
B. Bi ton gia cng co T bng thy lc
FNISH
/CLEAR,ALL
/TITLE, BLOW MOLD: REV A
C***, using shell element only C***,
AUTHOR: TRAN KHOA LUAT
/prep7
/light,1,1,0.7,-1,-1,-1
/PLOPT,info,1
/REPLOT C***,
TEST-B
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!!!!! UNIT UNIT UNIT !!!!!
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!Units Kg,mm,ms,Gpa
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!!!!! PARA PARA PARA !!!!!
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!wall thickness = 1.3
!lenght = 121mm
!outer diameter 24.1mm
!mean diamater 22.8mm
!unit: Kg,mm,ms,Gpa
/prep7
!feed parameters F1 =
0
F2 = 4
F3 = 12
F4 = 14.5
F5 = 18.5
!pressure parameters
P1 = 0
P2 = 0.0032
P3 = 0.045
P4 = 0.040
P5 = 0.040
thkm = 1.3
d0 = 24.1
l0 = 121
rdm = (d0-thkm)/2 l1
= l0/2
thkd = 0.001
rfil = 3
rd_1 = rdm + 0.5*(thkm+thkd) ! die rad

rd_2 = rdm - 0.5*(thkm+thkd) ! punch rad
fsc = 0.15 ! coeffient friction
k,1000,0,0,0
k,1001,l1,0,0
k,1002,0,l1,0
! punch k,1,0.75*l1,0.95*rd_2,0
k,2,l1 + 1.2*thkd,0.98*rd_2,0
k,3,l1 + 1.2*thkd,rd_2+thkm,0 l,1,2
l,2,3
! metal pipe
k,4,0,rdm,0
k,5,l1,rdm,0
l,4,5
! die
k,6,0,rd_1,0
k,7,l1,rd_1,0
k,8,rd_1,0,0
k,9,rd_1,35,0
l,6,7
l,8,9
!support plate
k,10,0,rd_1,0
k,11,rd_1-0.5*thkd,rd_1,0
l,10,11
lesize,1,10
lesize,2,,,3
arotat,1,2,,,,,1000,1001,-180,2 ! inter die
lesize,3,,,40,2
arotat,3,,,,,,1000,1001,-180,2 ! metal pipe
arotat,4,,,,,,1000,1001,-180,2 !
arotat,5,,,,,,1000,1002,90,1
arotat,6,,,,,,1000,1002,90,1 ! support plate
aptn,7,9
adele,11,12,1,1
afillt,13,14,rfil
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!!!!! TYPE, REAL, MAT, !!!!!
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
ET,1,163 KEYOPT,1,1,12
EDSHELL,20,-1,1,2,1,1
R,1 !metal
RMODIF,1,1,5/6,2,thkm,thkm,thkm,thkm,0
MP,DENS,1,8900e-9
MP,EX,1,119.86 MP,NUXY,1,0.31
TB,PLAW,1,,,2, TBDAT,1,0.4257
!k
TBDAT,2,0.2562 !n
!TBDAT,3,
!TBDAT,4,
TBDAT,5,0.116 !sy
!TBDAT,6,
!die
R,2
RMODIF,2,1,5/6,2,thkd,thkd,thkd,thkd,0, EDMP,RIGI,2,7,7
MP,DENS,2,7.850e-9
MP,EX,2,210
MP,NUXY,2,0.3
!Puch
R,3
RMODIF,3,1,5/6,2,thkd,thkd,thkd,thkd,0
EDMP,RIGI,3,5,7
MP,DENS,3,7.850e-9
MP,EX,3,210
MP,NUXY,3,0.3
!support sheet
R,4
RMODIF,4,1,5/6,2,thkd,thkd,thkd,thkd,0 EDMP,RIGI,4,6,7
MP,DENS,4,7.850e-9
MP,EX,4,210
MP,NUXY,4,0.3
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
!!! MESH
!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
! sheet metal
aatt,1,1,1,0
lesize,19,,,10,0.5
lesize,20,,,10,0.5
lesize,21,,,10,
lesize,22,,,10,
amesh,5,6
asel,s,,,5 esla,s
esel,r,cent,x,0,1.2*rd_1 esel,r,cent,y,0,rd_1
!EREFINE,ALL, , ,1,0,1,1 ALLSEL
!die AATT,2,2,1,0
lesize,23,,,20,0.25
lesize,24,,,20,0.25
lesize,27,,,10
lesize,28,,,10
AMESH,8
lesize,26,,,10
lesize,42,,,10,0.5
lesize,44,,,20,0.5
lesize,4,,,3
lesize,45,,,10
lesize,47,,,5
lesize,40,,,5
lesize,31,,,10
AMESH,11 AMESH,7
ASEL,S,,,9
AMESH,9
ESLA,S
!EREF,all, , ,1,0,1,1 ALLSEL
!punch aatt,3,3,1,0
lesize,11,,,10
lesize,14,,,10
lesize,12,,,10
lesize,15,,,10
lesize,13,,,10
LESIZE,16,,,10
amesh,1,4 asel,s,,,5,6
nsla,s,1 esln,s,,all
cm,int_elem,element
allsel
save
/prep7 EDPART,CREATE
EDCGEN,FOSS,1,2,fsc,fsc,0.5,0.067,20,,,,,0,1500,0,0
EDCGEN,FOSS,1,3,fsc,fsc,0.5,0.067,20,,,,,0,1500,0,0 EDCGEN,ASSC,
EDCONTACT,0.1,0,2,2,1,2,1,4,1
EDSP,ON,1,2,1,
EDSHELL,20,-1,1,2,1,1,
*Dim,time,array,5,1,1,,,,
*Dim,int_press,array,5,1,1,,,,
*Dim,push,array,5,1,1
*set,time(1,1,1),0
*set,time(2,1,1),1.2
*set,time(3,1,1),2.76
*set,time(4,1,1),3.10
*set,time(5,1,1),3.5
*set,int_press(1,1,1),p1
*set,push(1,1,1),-f1
asel,s,,,5,6 nsla,s,1
nsel,r,loc,x,0
dsym,symm,x, allsel,
nsel,r,loc,z,0
dsym,symm,z, allsel,
nsel,r,loc,x,l1
cm,endnode,nodes
allsel,
edload,add,press,1,int_elem,time,int_press,,,,,
edload,add,rbux,,3,time,push,,,,, edload,add,ux,,endnode,time,push,,,,,
EDMP,HGLS,1,0,0.1,1.5,0.06,,,
EDCTS,,0.9 TIME,3.5,
EDRST,100,
EDHTIME,200,
EDOUT,GLSTAT
EDOUT,MATSUM
EDOUT,RCFORC
EDOPT,add,,LSDYNA
EDDUMP,1,
finish
/config,nres,2000
/solu
EDADAPT,1,ON
EDADAPT,2,OFF
EDADAPT,3,OFF
EDCADAPT,0.5,5,1,3,0.5,3,,3,,,,,,
EDWRITE,LSDYNA,'file','k',' '
C. Chng trnh LS-DYNA
Chng trnh LSDYNA ban u da trn chng trnh phn t hu hn

DYNA3D do tin s John O. Hallquist ti phng th nghim quc gia Lawrence
Livermore (LLNL) vo nm 1976. DYNA3D c to ra nhm m phng va chm
trong cc th nghim qun s. Vo thi im , khng c chng trnh dng 3D
no kh nng m phng cc va chm trong khi cc chng trnh 2D t ra qu
ngho nn. DYNA3D s dng tch phn explicit m t cc vn ng lc hc
phi tuyn v c dng nhiu trong cc phn tch ng sut ca cu trc di nhiu
(ti) va chm khc nhau. Chng trnh ban u kh n gin do gii hn v phn
cng. Nhng nm sau , cng vi s pht trin ca my tnh DYNA3D tip tc ra
cc phin bn mi thm nhiu loi phn t bc cao c kh nng gii quyt cc vn
ngy cng phc tp. Nh mt kt qu tt yu v nhu cu tnh ton ca cc
ngnh cng nghip, Livermore Software Technology Corporation (LSTC) ra i
nhm tip tc pht trin v m rng chng trnh DYNA3D thnh LS-DYNA.
Hin nay, cng ty ANSYS tch hp chng trnh LS-DYNA v to thnh
chng trnh ANSYS/ANSYS-LSDYNA. Nhng bi ton in hnh ca LS-DYNA:
Bi ton tip xc (vd: cc chi tit my vi nhau)
Bi ton bin dng ln (vd: qu trnh dp kim loi)
Vt liu phi tuyn (vd: cc loi nha nhit do, cao su)
Cc bi ton va chm (vd: va chm t, va chm gia ngi v ti kh)
Cc ng dng trong cng nghip quc phng (vd: m phng cc v n)
Quy trnh gii mt bi ton bng modul Ls-Dyna trong ANSYS:
V chng trnh ANSYS tng ng v mt xy dng m hnh hnh hc v c
s dng th vin vt liu vi chng trnh Ls-Dyna nn khong 80% lnh ca Ls-
Dyna c h tr bi ANSYS. Sau khi tin hnh chia li v p t iu kin bin,
iu kin u, cc iu kin tip xc, cc iu kin kim sot hourglassing, gim
chn, khi lng, nng lngchng trnh ANSYS to ra mt tp tin c dng
*.k. Ta c th hiu chnh tp tin ny bng cch iu chnh cc th (card) ca n
v sau dng b gii LSDYNA solver gii. Ta tc ng vo qu trnh gii
bng cch dng cch khi ng (restart) cc qu trnh nhm loi b mt s lin kt
khng cn thit, thay i thuc tnh vt liu nh ha rn ( flexiable to rigid) hay l
chuyn i qua li gia thut ton Explicit v Implicit.
Ngoi ra, ANSYS/LS-DYNA cn cho php ngi dng nng cao hiu nng x l bi
ton bng ty chn HPC (High Performace Computing) c th iu chnh s nhn
x l khi dng my tnh n hoc x l song song bng nhiu my tnh.
Ph lc 1: B gii LS-DYNA Solver tch hp vo chng trnh ANSYS
Ph lc 2: Ty chn s nhn x l cho qu trnh tnh ton
D. Chng trnh HyperView
HyperView l mt sn phm ca cng ty Altair Engineering c tr s ti bang

Michigan, Hoa K. HyperView c to ra vi vai tr l mt cng c phn tch kt
qu trc quan, thn thin vi ngi dng. HyperView c kh nng c c nhiu
nh dng kt qu ca nhiu chng trnh tnh khc nhau nh ANSYS, LS-DYNA,
ADYNA, ABAQUS, NASTRANvi tnh nng biu din ha 3D nhanh chng
kt hp vi cc cng c ton hc phc tp to nn tnh tin li, r rng, linh hot
trong qu trnh phn tch d liu.
im ni bt ca HyperView l ngi dng c th tng tc bng giao din v

biu din mt lng ln cc hm kt qu v cc gi tr lin quan trong cng mt
thi gian mt cch t ng, v ly kt qu mt cch d dng v nhanh chng.
Ph lc 3: Giao din ca chng trnh HyperView

Mo Phong Mot So Qua Trinh Gia Cong AP Luc

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I HC QUC GIA THNH PH H CH MINH

TRNG I HC BCH KHOA

GVHD: PGS.TS. TRNG TCH THIN

GVHD: PGS.TS. Trng Tch Thin ii

NHIM V LUN VN TT NGHIP

Khoa: KHOA HC NG DNG

M PHNG MT S QU TRNH GIA CNG P LC

2. Nhim v (yu cu v ni dung ban u):

Ni dung yu cu LVTN c thng qua b mn.

TS. V CNG HA PGS.TS. TRNG TCH THIN

PHN DNH CHO KHOA, B MN

Lun vn c hon thnh l kt qu qu trnh hc tp v nghin cu trong nhng

Cng trong dp ny, ti xin chn thnh cm n gia nh v bn b, tp th lp c k

TP.HCM, thng 12 nm 2012

Trn Khoa Lut

Lun vn tp trung nghin cu qu trnh gia cng p lc vi hai bi ton dp su

T kha: L thuyt do, Sheet metal, Deepdrawing, HydroForming, Residual

CHNG 1: TNG QUAN V GIA CNG P LC ................................................. 1

1.1 Gii thiu .................................................................................................................. 1

1.2 Cc qu trnh gia cng p lc ph bin cho kim loi tm ....................................... 3

1.3 Tng quan v khun dp .......................................................................................... 7

CHNG 2: C S L THUYT ............................................................................... 13

2.1 M hnh ng x n trc trong chy do .............................................................. 13

2.2 Quan im Lagrange v quan im Euler v m t chuyn ng .............................16

2.3 Phng php phn t hu hn .............................................................................. 18

2.4 L thuyt tip xc va chm .................................................................................... 29

2.5 Chia li thch ng (Adaptive meshing) ............................................................... 43

CHNG 3: TNH TON V M PHNG BNG PHNG PHP PHN T

3.1 Tnh ton v m phng bi ton dp su ................................................................ 46

3.2 Phn tch nh hng ca mt s iu kin khc trong qu trnh dp .................. 86

3.3 M phng bi ton to co T bng thy lc ............................................................ 90

CHNG 4: KT LUN V KIN NGH ......................................................... 117

4.1 Kt lun................................................................................................................. 117

4.2 Kin ngh .................................................................................................. 117

TI LIU THAM KHO .............................................................................................. 119

A. Bi ton dp su .................................................................................................... 120

C. Chng trnh LS-DYNA ...................................................................................... 139

D. Chng trnh HyperView ..................................................................................... 142

CHNG 1: TNG QUAN V GIA CNG P LC

1.1 Gii thiu

GVHD: PGS.TS. Trng Tch Thin 1 SVTH: Trn Khoa Lut

vt tri so vi cc phng php khc nh c, ct gt. Trong iu kin sn xut

GVHD: PGS.TS. Trng Tch Thin 2 SVTH: Trn Khoa Lut

1.2 Cc qu trnh gia cng p lc ph bin cho kim loi tm

1.2.1 Qu trnh to phi (blanking and piercing)

Thng thng kim loi tm c bo qun dng cun, qu trnh u tin l

Hnh 1.1: Sn phm sau khi dp ct

1.2.2 Qu trnh un (bending)

Qu trnh un n gin nht l to np gp thng trn tm kim loi. c im

GVHD: PGS.TS. Trng Tch Thin 3 SVTH: Trn Khoa Lut

Hnh 1.2: Qu trnh to gc ln bng phng php un

1.2.3 Qu trnh p dn u (stretching)

y l qu trnh to hnh trong phn ln tm kim loi c ko dn v un

Hnh 1.3: Qu trnh p dn u

1.2.4 Qu trnh to l (hole extrution)

Qu trnh m rng l c sn v to thm vin (flanger) mt pha ca phi.

GVHD: PGS.TS. Trng Tch Thin 4 SVTH: Trn Khoa Lut

Hnh 1.4: Kt qu qu trnh to l

1.2.5 Qu trnh dp (stamping, draw die forming)

Qu trnh dp c xem l qu trnh gia cng p lc rng ri nht. N c th

- Ma st gia phi v khun bin i lin tc

- Cc qu trnh gin n v nhit, ch dp

- Hin tng n hi (springback) sau khi tho khun

Trong qu trnh dp to hnh, c ba qu trnh c bn: