锻压技术

大尺寸多环绕加强内蒙皮橡皮囊成形缺陷控制

英文标题：Control on defects in rubber bladder forming for reinforced inner skin with large-size and multiple surrounds

作者：白颖钟李欣王伟张立邱晞

分类号：TG386

出版年,卷(期):页码：2021,46(11):168-175

摘要：

针对大尺寸多环绕加强内蒙皮加强筋深度超出铝合金材料一次拉伸变形极限，以及多筋结构成形应力无法释放、成形后回弹大等难题,借助于 PAMSTAMP模拟软件建立有限元模型，对不同结构毛坯橡皮囊成形的起皱、破裂等缺陷进行数值分析，研究零件多环绕深筋结构对橡皮囊成形材枓流动的影响规律。结果发现，增加支撑压板辅助装置可有效地控制首道次橡皮囊成形材料厚度减薄率，从而优化毛坯、模具结构和压边力等参数，并通过试验加以验证。结果表明，柔性支撑的多道次橡皮囊成形内蒙皮加工方法减小了薄壁深筋结构材料单次变形极限，提高了传统橡皮囊成形深腔结构的高度极限，解决了落压成形工序繁琐、周期长、起皱严重、表面质量差等瓶颈问题。

For the problems that the depth of strengthening rib for reinforced inner skin with large-size and multiple surrounds exceeded the one-time tensile deformation limit of aluminum alloy material, the forming stress of multi-rib structure could not be released and the springback after forming was too large, by the simulation software PAMSTAMP, a finite element model was established to numerically analyze the defects of wrinkles and ruptures of the blanks with different structures during the rubber bladder forming, and the influence laws of multiple surrounds and deep rib structure for part on the material flow during the rubber bladder forming were studied. Then, it was found that the material thickness reduction rate of the first-pass rubber bladder forming could be effectively controlled by adding the supporting pressure plate auxiliary device, and the parameters of blank, die structure and blank holder force were optimized, which was verified by experiments. The results demonstrate that the inner skin processing method of multi-pass rubber bladder forming with flexible support reduces the single deformation limit of thin-walled deep rib structure and improves the height limit of deep cavity structure in the traditional rubber bladder forming, and the bottleneck problems, such as tedious process, long period, serious wrinkling and poor surface quality of pressure drop forming, are solved successfully.

基金项目：

作者简介：白颖（1972-），女，学士，研究员级高工，E-mail：baiyingsyh@163.com

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