Big Composite Beam Roller-Straightening Research And Finite Element Analysis

SL1 type side beam of electric power engine is a composite beam which welded by formed beam and side plate. It's the main bearing beam of new electric power engine vehicle box. it's important for engine integrated structure,assembly parts and engine run speed. After formed and storage, the formed beam and side plate will distort. After welded two parts together, they also would distort.so the composite beam need roller-straightening.The composite beam is hollow, after straighten it would stave, so the straightening is difficult.although there is theory formula but without unite of theory formula, simulation and practice.In this article, the roller-straightening machine design is according to the structure dimension and original distortion of the composite beam, also followed the theory formula of roller-straighten.The equivalent section beam and the composite beam simulation study of static analysis are using the FEA(finite element analysis) software ANSYS, the simulated result is compared with theory calculation value.The dynamic simulation of roller-straightening process is using the LS-DYNA software, analysis the distortion and stress of composite beam in different time. Observe the stress and distortion variety in the straightening process by selecting typical element. Also analysis the clearance between composite beam and rollers which will influence the bending of composite beam side plate (side plate of formed beam). The dynamic simulation just considers the side bending which is 2-D bending.Compiled the calculation program of roller-straightening according to theory formula. Complete the precision calculation of the straightening force and the adjective rollers displacement, confirm the needed straightening times.