锻压技术

基于有限元分析的贮箱瓜瓣凸孔工艺优化

英文标题：Optimization on holeflanging process for storage tank melon flap based on finite element analysis

作者：韩磊张下陆卢松涛胡军辉彭江涛

分类号：TG386.49

出版年,卷(期):页码：2019,44(8):49-54

摘要：

通过利用有限元分析软件ABAQUS模拟了贮箱瓜瓣2219铝合金材料凸孔成形过程，仿真分析了材料在不同凸孔工艺参数（预制孔直径、工艺圆角及板材壁厚）条件下所受的应力以及凸孔最终成形的质量。分析结果表明，合理设置预制孔直径、工艺圆角以及凸孔区域板材壁厚（预制孔直径d=Φ 60 mm、工艺圆角R=2 mm、板材壁厚δ=6 mm）将提高凸孔成形质量，同时有助于降低材料所受的最大残余应力。最后，根据仿真过程中的各项凸孔工艺参数，进行了以2219铝合金材料为母材的贮箱瓜瓣凸孔试验，试验过程中通过对预制孔直径、工艺圆角的调节，分析了相应工艺参数对凸孔最终成形质量的影响，通过对比分析得出的试验结果与有限元分析结果保持一致，并得出贮箱瓜瓣厚度8 mm状态下，成形Φ 75 mm凸孔的合理工艺参数为预制孔直径Φ 62 mm，且边缘充分圆滑过渡。

The holeflanging process of 2219 aluminum alloy storage tank melon flap was simulated by finite element analysis software ABAQUS, and the stress under different holeflanging process parameters (prepunching hole diameter, process round corner and wall thickness of sheet material) and the final forming quality of holeflanging were simulated analyzed. The analysis results show that the reasonable setting with the prepunching hole diameter d=Φ 60 mm, the process round corner R=2 mm and the wall thickness of sheet material δ=6 mm around the holeflanging area improves the holeflanging forming quality. At the same time, it can also help to reduce the maximum residual stress of material. Finally, the holeflanging experiments for storage tank melon flap with the base material of 2219 aluminium alloy were conducted based on various holeflanging process parameters in the simulation process, and the influences of process parameters on the final forming quality of holeflanging were analyzed by the adjustment of prepunching hole diameter and process round corner. Furthermore, the experimental results are consistent with the results of finite element analysis, and the reasonable prepunching hole diameter for making Φ75 mm holeflanging with 8 mm thickness of storage tank melon flap is Φ62 mm, and the edges are smooth sufficiently.

基金项目：

航天一院工艺改进项目（Y4170153C）

作者简介：韩磊（1987-），男，硕士，工程师 E-mail：hanltop@126.com

参考文献：

[1]王金萍. 汽车用2219铝合金搅拌摩擦焊组织性能研究及仿真分析[J]. 热加工工艺, 2014, 43(3)：196-198.

Wang J P. Numerical simulation and study on microstructure and properties of friction stir welding for aluminum alloy [J]. Hot Working Technology, 2014, 43(3)：196-198.

[2]孙世烜, 张勤练, 李延民, 等. 2219铝合金变极性TIG横焊接头组织与性能研究[J]. 航空制造技术, 2015, (1)：5-10，14.

Sun S H, Zhang Q L, Li Y M，et al.Research on microstructures and mechanical properties of horizontal position welding joints of 2219 aluminum alloy by variable polarity TIG [J].Aerospace Manufacturing Technology，2001, (1)：5-10，14.

[3]江斌, 单长智, 王立娟. 2219合金熔铸工艺的改进[J]. 轻合金加工技术, 2001, (8)：15-18.

Jiang B, Shan C Z, Wang L J. Improvement on 2219 alloy meltingcasting process [J]. Light Alloy Fabrication Technology,2001, (8)：15-18.

[4]Silva M B , Martinho T M , Martins P A F . Incremental forming of holeflanges in polymer sheets[J]. Materials and Manufacturing Processes, 2013, 28(3):330-335.

[5]Huang Y M , Chien K H . The formability limitation of the holeflanging process[J]. Journal of Materials Processing Technology, 2001, 117(1):43-51.

[6]Bambach M, Voswinckel H, Hirt G. A new process design for performing holeflanging operations by incremental sheet forming [J]. Procedia Engineering, 2014, 81:2305-2310.

[7]Cristino V A, Montanari L, Silva M B, et al. Fracture in holeflanging produced by single point incremental forming[J]. International Journal of Mechanical Sciences, 2014, 83(83):146-154.

[8]郭飞鹏, 李大永, 唐鼎. 空调翅片的翻边孔多道次成形模拟[J]. 锻压技术, 2017, 42(5)：164-170.

Guo F P, Li D Y, Tang D. Simulation on multistep holeflanging for airconditioning fins[J].Forging & Stamping Technology, 2017, 42(5)：164-170.

[9]Yu N. Tipradius effect in finite element modeling of sub50 nm shallow nanoindentation[J]. Thin Solid Films, 2004, 450(2):295-303.

[10]Han L, Zhao H, Zhang Q, et al. Research on influences of contact force in chemical mechanical polishing (CMP) process[J]. AIP Advances, 2015, 5(4):041305.

[11]Zhao H , Shi C , Zhang P, et al. Research on the effects of machininginduced subsurface damages on monocrystalline silicon via molecular dynamics simulation[J]. Applied Surface Science, 2012, 259:66-71.

[12]韩磊, 孙良杰, 王龙, 等. 均匀网格壁板三点弯曲过程的有限元分析与试验研究[J]. 塑性工程学报, 2018, 25(3)：23-29.

Han L, Sun L J, Wang L, et al. Finite element analysis and experimental research of threepoint bending process for uniform mesh panels[J]. Journal of Plasticity Engineering,2018, 25(3)：23-29.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】