锻压技术

汽车结构钢大曲率变截面管件充液成形工艺优化

英文标题：Optimization on hydroforming process of large-curvature variable-section pipe for automobile structural steel

作者：张三敏郎利辉矫志辉张艳峰吴家文

单位：北京航空航天大学天津市天锻压力机有限公司天津天锻航空科技有限公司隆昌山川机械有限责任公司

分类号：TG394

出版年,卷(期):页码：2021,46(4):96-101

摘要：

大曲率变截面复杂薄壁钢管件被广泛应用于汽车行业，但因其成形难度较高，一直采用传统的分体成形，针对这一技术难题，采用一模两件整体充液成形方式，以提高零件的成形质量及使用寿命，并节约成本。通过有限元分析软件，建立大曲率变截面复杂薄壁钢管件充液成形的有限元模型，通过分析不同的预成形阶段压力加载路径，以及补料阶段的补料压力对壁厚分布的影响规律，并通过有限元模拟对零件成形的破裂及起皱的失稳情况进行分析，进而优化出最佳的成形工艺参数，得到该零件最优的成形阶段压力加载路径，以及最优的补料压力为80 MPa。并且根据优化的工艺参数制得合格的目标零件，进一步验证了成形方案及成形工艺参数的可行性。

The complex thin-walled steel pipes with large-curvature and variable-section are widely used in the automotive industry, but the traditional split forming has been adopted due to their high forming difficulty. For the above technical problem, the integral hydroforming method of one-mold with two pieces was used to improve the forming quality and service life of parts as well as save costs. Then, the finite element model of complex thin-walled steel pipe with large-curvature and variable-section in hydroforming was established by finite element analysis software, and the influence laws of different pressure loading paths in pre-forming stage and feeding pressures in feeding stage on the wall thickness distribution as well as the fracture and wrinkle of formed part were analyzed through the finite element simulation, the best forming process parameters were optimized, the best pressure loading path during the forming stage of part was obtained, and the optimal feeding pressure was 80 MPa. Furthermore, according to the optimized process parameters, the qualified target parts were obtained, and the feasibility of the forming scheme and forming process parameters was further verified.

基金项目：

国家自然科学基金资助项目（51675029）

张三敏（1997-），女，硕士研究生 E-mail：17766589623@163.com 通讯作者：郎利辉（1970-），男，博士，教授 E-mail：lang@buaa.edu.cn

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