Study On The Bending Deformation And Its Effect In Busbar Vertical Bending

With the rapid increase of national electricity consumption,Busbar has been more and more widely used as the carrier of high current transmission.Bending,as an inevitable process in the use of Busbar,has an important influence on the quality of busbar forming.At present,the research on busbar bending forming is mainly focused on flat bend,and there is relatively little research on vertical bending,the main problem in bus bending forming in China is the warping deformation of busbar in the forming process,which seriously affects the normal installation of Busbar,and will reduce its conductivity and service life.Therefore,it is very necessary to study the warping deformation in the process of bus vertical bending forming deeply.Taking 1060 Pure aluminum busbar as the research object,this paper studies the warping deformation in the process of bus vertical bending forming by means of theoretical analysis and finite element simulation,analyzes the influence of different width ratio of bus,different bending angle forming quality,and validates it by experiment.At the same time,the method of applying side pressure from the upper surface of busbar to suppress warping in the process of busbar bending forming is put forward,and the influence law of side pressure on the warping deformation of busbar is obtained.The main research contents of this paper are as follows: Firstly,the bending forming and instability theory of sheet metal are introduced,and the warping problem in bus vertical bending forming is analyzed.It is found that the main factors affecting the warping deformation in the process of busbar forming are the tangent modulus and the width ratio of the busbar,and the greater the tangent modulus and the width ratio of the busbar,the more likely it is to have warping instability.The results of energy method analysis show that the applied lateral pressure can effectively suppress warping deformation and improve the forming quality of busbar.Through ABAQUS software,the process of bus vertical bending forming is simulated,and the equivalent plastic stress,equivalent plastic strain and the deformation of bus thickness in vertical plane are analyzed in the process of bending forming of busbar.It is found that the smaller the width ratio of busbar,the lower the initial moment of warping in the process of bending forming,the smaller the growth rate of busbar thickness when the bending angle is the same.In the initial stage of busbar forming,the thickness direction decreases gradually with the bending angle,and when the bending reaches a certain angle,with the decrease of bending angle,the warping amount in the direction of bus thickness increases rapidly,and the growth rate becomes faster and more fast.The influence law of busbar width ratio,bending angle,side pressure size and force position on warping deformation is designed,and the corresponding curves are fitted by MATLAB software to explore the measures that can effectively improve the quality of busbar bending forming parts.It is found that the lateral pressure has an important influence on warping in the process of busbar bending,and the side pressure is small,which can not effectively restrain the warping in busbar bending forming,and with the increase of side pressure,the warping degree of busbar is effectively controlled,but it is not the larger the side pressure,the greater the lateral pressure will lead to the abnormal deformation of busbar Causes direct damage to the surface of the busbar.In addition,the different force positions of the lateral pressure will have no effect on inhibiting warping.