锻压技术

复杂半管零件的充液拉深成形工艺设计

英文标题：Forming process design of hydroforming for complex semi-tube parts

作者：张凌云刘国庆王文远范作鹏

单位：沈阳航空航天大学大连长丰实业总公司中航工业沈阳飞机工业（集团）有限责任公司

分类号：TG386

出版年,卷(期):页码：2018,43(4):100-104

摘要：

针对当前复杂半管零件成形难、成形质量差的问题，采用充液拉深成形工艺解决复杂半管零件的成形难题。在采用正交试验以及数值模拟软件的基础上，根据对不同试验方案模拟结果的壁厚分析，得到了复杂半管零件充液拉深成形的最佳成形参数，即液室压力为15 MPa、凹模圆角半径为15 mm、凸模摩擦系数为0.1、凹模摩擦系数为0.1。建立了以抛物线形过渡工艺补偿面的凸模端口结构模型，确定了最优液室压力加载路径为PPB方式，并对5A02-O态铝合金板材充液拉深成形的复杂半管零件进行了工艺试验验证。结果表明，充液拉深成形工艺可有效地解决复杂半管零件的成形问题，成形出零件的最小壁厚为1.65 mm，满足工业要求。

For the problems that the current complex semi-tube parts are difficult to be formed and the forming quality is poor, a forming process of hydrforming was proposed to solve the forming problems of complex semi-tube parts. Based on the orthogonal test and numerical simulation software, according to the wall thickness analysis of simulation results for different test schemes, the best forming parameters of hydroforming for complex semi-tube parts were obtained with the chamber pressure of 15 MPa, die corner radius of 15 mm, punch friction coefficient of 0.1 and die friction coefficient of 0.1. Then, a structure model of punch port with the process compensation surface of paraboloid-shaped transition was established, and the optimal loading path of chamber pressure was determined as PPB mode. Furthermore, the hydroforming of complex semi-tube parts for aluminum alloy 5A02-O was verified by process test. The results show that the hydroforming process can effectively solve the forming problems of complex semi-tube parts, and the minimum wall thickness of formed parts is 1.65 mm which meets the industrial requirements.

基金项目：

张凌云（1963- ），男，博士，教授，硕士生导师；E-mail：zhangly79@163.com；通讯作者：刘国庆（1991- ），男，硕士研究生；E-mail：sdcwlgq@outlook.com

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