锻压技术

关键工艺参数对铝合金斜法兰非轴对称盒形件充液成形的影响

英文标题：Influence of critical process parameters on hydroforming for aluminum alloy nonaxisymmetric box with oblique flange

作者：郎利辉巫永坤王永铭刘宝华李磊

单位：北京航空航天大学首都航天机械公司天津天锻航空科技有限公司

关键词：铝合金斜法兰充液成形预胀形数值模拟

分类号：TG394

出版年,卷(期):页码：2018,43(6):47-52

摘要：

铝合金斜法兰非轴对称深腔盒形件成形过程中受力变形复杂。通过理论分析计算、有限元分析软件Dynaform的数值模拟及试验，对成形工艺进行了优化。针对该零件充液拉深过程易出现的破裂、起皱现象，研究了预胀形高度、预胀形液室压力、液室压力加载路径对零件法兰最高处D侧与最低处B侧凸模圆角区域在板料成形过程中壁厚变化的影响。结果表明，预胀形高度越高或预胀形液室压力过大，零件B侧与D侧凸模圆角在成形后壁厚减薄越严重；预胀形高度过低也会导致D侧凸模圆角在成形后发生严重减薄。预胀形结束后，液室压力加载过快，易发生褶皱，达到临界液室压力后，可以有效抑制板料壁厚过度变薄。

The stress and deformation during sheet hydroforming process of aluminum alloy nonaxisymmetric box with oblique flange were complicated, and the forming process was optimized by theoretical analysis and calculation, numerical simulations using software Dynaform and experiments. Based on cracking and wrinkling easily occurred in the hydrodynamic drawing process, the influences of prebulging height, prebulging cavity pressure, and loading path of cavity pressure on wall thickness variation at punch fillet of the highest corner D and the lowest corner B were investigated. The results indicate that the minimum wall thickness at punch fillet of corner B and corner D reduces with the increase of prebulging height or the oversize of prebulging pressure. Too low prebulging height also causes the wall thickness at punch fillet of corner D to thin excessively. Wrinkling easily occurs if the cavity pressure is loaded too fast after prebulging. After the critical cavity pressure is reached, the wall thickness of the sheet can be effectively restrained to thin excessively.

基金项目：

国家科技重大专项（2014ZX04002-071）

郎利辉（1970-），男，博士，教授；Email：lang@buaa.edu.cn；通讯作者：巫永坤（1992-），男，硕士研究生；Email：yongkunwu33@163.com

参考文献：

［1］Lang L H, Zhang S H, Kang D C, et al. About sheet hydroforming and hydromechanicaldeep drawing without draw die
［J］. Journal of Plasticity Engineering, 2002, 9(4): 29-34.

［2］Lang L H, Danckert J, Nielsen K B. Investigation into the effect of prebulging during hydromechanical deep drawing with uniform pressure onto the blank
［J］. International Journal of Machine Tools and Manufacture, 2004, 44 (6): 649-657.

［3］鄂大辛，水野高爾. 矩形盒拉深成形中的几何形状效应
［J］. 锻压技术，2004，29(3)：30-33.

E D X, Mizuno T. Geometric shape effect of rectangular case drawing forming
［J］. Forging & Stamping Technology, 2004, 29(3): 30-33.

［4］马丽霞，王凤琴，赵军. 盒形件主要变形区的应力近似理论解析
［J］. 机械工程学报，2005，41(7)：56-61.

Ma L X, Wang F Q, Zhao J. Approximate analysis of stress in main deformation area for a rectangular box
［J］. Chinese Journal of Mechanical Engineering, 2005, 41(7): 56-61.

［5］郎利辉，王永铭，谢亚苏，等. 铝合金盒形件充液成形法兰变形特性及其失稳影响分析
［J］. 材料科学与工艺，2013，21(4)：37-43.

Lang L H, Wang Y M, Xie Y S, et al. The flange deformation characteristics and its effect on failure in the hydroforming process of aluminum alloy rectangular cup
［J］. Materials Science & Technology, 2013, 21(4): 37-43.

［6］Lang L H, Wang Y M, Xie Y S, et al. Prebulging effect during sheet hydroforming process of aluminum alloy box with unequal height and flat bottom
［J］. Transactions of Nonferrous Metals Society of China, 2012, 22(22): 302-308.

［7］Meng B, Wan M, Yuan S, et al. Influence of cavity pressure on hydrodynamic deep drawing of aluminum alloy rectangular box with wide flange
［J］. International Journal of Mechanical Sciences, 2013, 77(77): 217-226.

［8］Vollertsen F, Lange K. Process layout avoiding reverse drawing wrinkles in hydroforming of sheet metal
［J］. CIRP AnnalsManufacturing Technology, 2002, 51(1): 203-208.

［9］Hama T, Hatakeyama T, Asakawa M. Finiteelement simulation of the elliptical cup deep drawing process by sheet hydroforming
［J］. Finite Elements in Analysis and Design, 2007, 43(3): 240-243.

［10］苑世剑. 现代液压成形技术
［M］. 北京：国防工业出版社，2009.

Yuan S J. Modern Hydroforming Technology
［M］. Beijing: National Defense Industry Press, 2009.

［11］郎利辉，张文尚，刘康宁，等. 液室压力对异形长法兰盒形件充液成形过程的影响
［J］. 锻压技术，2016，41(9)：41-45.

Lang L H, Zhang W S, Liu K N, et al. Influence of cavity pressure on boxshaped part with specialshaped long flanges in hydroforming process
［J］. Forging & Stamping Technology, 2016, 41(9): 41-45.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】