锻压技术

基于有限元的铝合金发动机盖外板充液成形

英文标题：Hydroforming for aluminium alloy engine cover outer plate based on FE

作者：杨文江崔礼春张稳定佘威

分类号：TG389

出版年,卷(期):页码：2020,45(9):123-129

摘要：

应用有限元模拟技术，对铝合金发动机盖外板充液成形过程进行研究，既利用“摩擦保持”效应减少零件表面出现滑移线的风险，又避免该效应产生的零件减薄不足的问题。通过建立铝合金发动机盖外板的有限元模型，对压边力、液室压强加载曲线等进行正交试验优化，模拟不同参数下的成形缺陷，最终得到最优液室压强加载曲线，即压边力设置为1250 kN，成形至115 mm时液室压强加载至5 MPa并保持至成形完成、到底后主动加压至14 MPa。开发模具实物后，试验验证结果与有限元模拟基本吻合，得到了A面品质、减薄率等符合要求的合格零件。

Using finite element simulation technology to study the hydroforming process of aluminum alloy engine cover outer plate, it not only uses the ‘friction retention’ effect to reduce the risk of slip lines on the surface of part, but also avoids the problem of insufficient thinning of part caused by this effect. Therefore, by establishing a finite element model of aluminum alloy engine cover outer plate, the blank holder force and hydraulic loading curve were optimized by the orthogonal experiments, and the forming defects under different parameters were simulated. Finally, the optimal hydraulic loading curve was obtained, namely, the blank holder force was set to 1250 kN, when the forming depth was 115 mm, the hydraulic pressure was loaded to 5 MPa and maintained until the forming was completed, and then it was actively pressurized to 14 MPa. Furthermore, after the die was developed, the test verification results were basically consistent with the finite element simulation, and the qualified parts with A-side quality and thinning rate meeting the requirements were obtained.

基金项目：

国家科技重大专项（2014ZX04002041）

杨文江（1970-），男，学士，高级工程师 E-mail：632390720@qq.com

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