锻压技术

大径厚比超薄铝合金构件3D增量成形规律

英文标题：3D incremental forming law of ultra-thin aluminum alloy components with large diameter-thickness ratio

作者：李岩1 张瑶1 庞秋2 胡志力1 3 4

单位：1.湖北隆中实验室 2.武汉科技大学机械自动化学院 3.武汉理工大学现代汽车零部件技术湖北省重点实验室 4.武汉理工大学湖北省材料绿色精密成形工程技术研究中心

分类号：TG386

出版年,卷(期):页码：2023,48(5):193-204

摘要：

传统采用的厚板成形后再铣削加工的大径厚比（≥1500∶1）超薄铝合金构件的制造方式，存在工序长、效率低、成本高等问题，因此，采用无需使用模具的、工艺柔性高的3D增量成形技术。以卫星天线反射面为对象，通过实验研究了不同参数的大径厚比（≥1640∶1）超薄铝合金构件的3D增量成形规律，采用Abaqus模拟分析了3D增量成形过程中的塑性应变以及板料减薄情况。结果表明：在大径厚比超薄铝合金构件3D增量成形过程中出现了破裂和起皱两种缺陷，通过分析缺陷成形机理和板料偏移规律发现，当层进给量或构件壁角过大时，板料容易失稳，易产生缺陷。最后，通过进行小层进给量（0.05 mm）的双道次成形，降低了板料成形时的应变，成功加工出无缺陷的大径厚比超薄铝合金3D增量成形构件。

The traditional manufacturing mode of ultra-thin aluminum alloy components with large diameter-thickness ratio (≥1500∶1) by milling after thick plate forming has problems such as long process, low efficiency and high costs. Therefore, the 3D incremental forming technology that does not need to use dies and has high process flexibility is adopted. For the reflector of satellite antenna, the law of 3D incremental forming for ultra-thin aluminum alloy components with large diameter-thickness ratio (≥1640∶1) of different parameters was studied by experiments, and the plastic strain and sheet metal thinning in the 3D incremental forming process were analyzed by Abaqus simulation. The results show that cracking and wrinkling defects appear in the 3D incremental forming process for ultra-thin aluminum alloy components with large diameter-thickness ratio, and the analysis on the forming mechanism of defects and the sheet metal offset law reveal that when the layer feeding amount or the wall angle of the component is too large, the sheet metal is prone to instability and produce defects. Finally, through double-pass forming with small layer feeding amount (0.05 mm), the strain of sheet metal during forming is reduced, and the defect-free ultra-thin aluminum alloy 3D incrementally formed component with large diameter-thickness ratio is successfully processed.

基金项目：

湖北隆中实验室自主创新研究项目（2022ZZ-04）；湖北省自然科学基金资助项目（2021CFB523）；湖北省重点研发计划项目（2021BAA200）；湖北省科技重大项目（2022AAA001）

作者简介：李岩(1998-)，男，硕士研究生,E-mail：yanlidk@126.com;通信作者：胡志力(1983-)，男，博士，博士生导师，教授,E-mail：zhilihuhit@163.com

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