锻压技术

铝合金复杂曲面薄壁罩体充液拉深失稳控制技术

英文标题：Failure control on hydroforming process of thin-walled aluminum alloy with complex surface covers

单位：首都航天机械公司

分类号：TG386

出版年,卷(期):页码：2017,42(9):69-73

摘要：

以某典型铝合金复杂曲面薄壁罩体为研究对象，采用数值模拟与工艺试验相结合的方法分析了凸模初始反胀位置与液室压力对成形失稳的影响规律，优化了成形工艺参数。结果表明，当凸模初始反胀位置低于凹模型面时，凸模进入凹模时悬空区板料没有液室压力的作用，悬空区板料处于一拉一压的应力状态，悬空区容易起皱；当凸模初始反胀位置在凹模型面上方时，凸模进入凹模时悬空区板料已经受到液室压力的作用，处于双向拉应力状态，因此可以抑制悬空区起皱；当液室压力较高时，悬空区板料承受较大的拉应力容易破裂。合理控制凸模初始反胀位置与液室压力可以消除悬空区起皱与破裂。

For one typical thin-walled aluminum alloy cover with complex surface, the influences of the punch initial reverse bugling position and the die cavity pressure on wrinkle were analyzed by numerical simulation and experiment method, and the process parameters were optimized. The results indicate that if the punch initial reverse bugling position is below the die surface, there is no pressure in the die cavity with the punch entering the die, and the unsupported blanks are subjected to tensile stress along one direction and compressive stress along another direction and easy to wrinkle. If the punch initial reverse bugling position is above the die surface, the unsupported blanks have been acted by the pressure in the die cavity with the punch entering the die and subjected to bidirectional tensile stress. Thus, the wrinkle can be controlled. If the die cavity is over high, the unsupported blanks will suffer higher tensile stress, and crack is easy to occur. The unsupported blank wrinkle and crack can be eliminated by a reasonable control on the punch initial reverse bugling position and the die cavity pressure.

基金项目：

民用航天技术预先研究项目（科工一司（2014）618号）

王永铭（1982-），男，博士，工程师 E-mail：wangyongming211@163.com

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