锻压技术

大型铝镁合金法兰盘镦冲成形超声探伤缺陷分析及控制

英文标题：Ultrasonic flaw detection analysis and control on a large-scale aluminum-magnesium alloy flange in upsetting and punching process

作者：王玉弟1 李保先1 刘恒1 房超2 亓效刚2 王广春2

单位：1. 山东瑞烨新能源装备有限公司2. 山东大学材料科学与工程学院

关键词：铝合金法兰盘冲孔缺陷控制流动状态超声探伤

分类号：TG319

出版年,卷(期):页码：2023,48(8):11-16

摘要：

针对大型5083铝镁合金法兰盘自由锻镦粗与冲孔成形过程中近内孔区域超声探伤出现的质量问题，建立了镦粗后饼坯冲孔有限元分析模型，模拟获得了冲孔过程法兰坯近内孔区域材料的流动规律，分析得出,法兰坯近内孔区域超声探伤质量缺陷为反面压平过程中近内孔区域材料流动存在径向分流所致。基于上述分析，提出对现行的正向冲孔-反面压平-连皮冲除工艺流程中的反面压平工序进行调整，即在反面压平工序中留存正向冲孔的冲子以约束近内孔区域材料的内流。进一步模拟表明，改进后的冲孔工艺能够显著改善近内孔区域材料的流动状态，规避了导致近内孔区域质量缺陷的径向分流不利因素。生产实际表明，调整后的工艺方案使得大型法兰盘镦冲成形过程中近内孔区域缺陷问题得到了有效解决。

Aiming at the quality problems of ultrasonic flaw detection in the area near inner hole during the upsetting and punching process of free forging for large-scale 5083 aluminum-magnesium alloy flange, a finite element analysis model for the punching billet after upsetting was established, and the punching process was simulated to obtain the flow law of the material in the area near inner hole of flange billet. Then, it is concluded that the ultrasonic flaw detection quality defect in the area near inner hole of flange billet was caused by the radial shunt of the material flow in the area near inner hole during the reverse flattening process. Furthermore, based on the above analysis, it was proposed to adjust the reverse flattening process in the current process flow of forward punching,reverse flattening and trimming, that is, to keep the punch of forward punching in the reverse flattening process to constrain the inflow of material in the area near inner hole. The further simulation results show that the improved punching process can significantly improve the flow state of material in the area near inner hole and avoid the unfavorable factors of radial shunt that lead to the quality defects in the area near inner hole. The actual production shows that the adjusted process scheme effectively solves the problems of defects in the area near inner hole during the upsetting and punching process of large-scale flange.

基金项目：

山东省科技型中小企业创新能力提升工程项目（2022TSGC2122）

作者简介：王玉弟（1969-），男，硕士，高工,E-mail：wangydjn@126.com;通信作者：王广春（1966-），男，博士，教授,E-mail：wgc@sdu.edu.cn

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