考虑接触摩擦的金属捻线捻制成形过程计算机模拟

建立了捻线捻制成形过程中的接触摩擦模型，采用小球分裂算法和Augmented Lagrangian法进行接触搜索和接触力计算。提出钢丝绳捻制成形计算机模拟的系统模型，系统能够生成可被ANSYS直接调用进行非线性分析的APDL，数据文件。对钢丝绳一次捻制成形过程进行了模拟计算。研究结果表明，非零自扭转系数较自扭转系数取值0．0时，相应的法向接触压力和摩擦接触应力的值较大，且接触应力沿螺旋线呈条状分布；非零摩擦系数与无摩擦条件相比，相应捻制加工应力应变的值较大，且自扭转系数等于1．0时，线截面内的剪应力最小，塑性区对弹性区的制约较小，弹性恢复较大；考虑摩擦时钢线表面的轴向残余应力计算结果比无摩擦条件下的计算结果更接近实验结果。

Numerical Simulation for Laying Wire Rope with Friction Contact

Friction contact model was presented for laying wire rope. The Splitting-pinball algorithm for contact searching and the Augmented Lagrangian method to calculate the contact forcewere described. System model for laying wire rope was brought forward. And the system could create APDL external files accessed by ANSYS for non-linear analysis. FE simulation of a simple wire strand in once laying was given. And the results show that the values of normal pressure and friction pressure with nonzero self-rotating ratio are larger than those without self-rotating ratio. And the distribution of contact pressure is band shape along the helix. The values of forming stress and strain with nonzero friction coefficient are larger than those without friction. And when self-rotating ratio equals 1.0, the shear stress is the smallest and restriction of plastic area to elastic area is less, which means that there is large elastic spring back. For the residual stress of helical wire in the end of laying process, the computed results with nonzero friction coefficient are in better agreement with the experimental results than those without friction.