锻压技术

大型复杂型面动车车头零件快速超塑成形工艺研究

英文标题：Research on rapid superplastic forming process for high-speed train head part with large and complex surface

作者：杨代立1 张开佳1 杜志豪2 陈冉冉3 4 周彤旭3 4 王春旭3 4 王国峰3 4

单位：1. 南京雷尔伟新技术股份有限公司2. 南阳师范学院机电工程学院 3.哈尔滨工业大学材料科学与工程学院 4. 哈尔滨工业大学金属精密热加工国防重点实验室

分类号：TG306

出版年,卷(期):页码：2023,48(8):83-89

摘要：

以动车车头左前侧壁板为研究对象，对铝合金左前侧壁板的快速超塑成形工艺进行了研究。基于左前侧壁板零件的三维形状，设计了快速超塑成形凸模和凹模，采用凸模成形，以壁板内型面作为凸模主要型面。利用MSC.MARC软件对左前侧壁板的热冲压、反胀超塑成形和正胀超塑成形阶段进行有限元分析，选择合适的反胀时间以控制反胀厚度，正胀实现零件的最终成形，最薄部位位于零件加工余量处，最大减薄率为21%，局部有聚料现象。之后进行了左前侧壁板快速超塑成形实验，在上端和前端中部有褶皱现象，与有限元分析结果基本吻合，对成形过程进行工艺改进后，成功地制造了表面质量良好的左前侧壁板。最后，对成形后材料的力学性能、零件的厚度分布和形状精度进行了测量。

For the left front side panel of high-speed train head, the rapid superplastic forming process of left front side panel for aluminum alloy was studied. Then, based on the 3D-shape of the left front side panel part, the punch and die for rapid superplastic forming were designed, the punch forming was used, and the inner profile of panel was used as the main profile of punch. Furthermore, the finite element analysis on the hot stamping, reverse bulging superplastic forming and direct bulging superplastic forming stages of the left front side panel was carried out by software MSC.MARC, the appropriate reverse bulging time was selected to control the reverse bulging thickness, the final forming of the part was realized by the direct bulging, the thinnest position was located in the machining allowance of the part, the maximum thinning rate was 21%, and there was a local accumulation phenomenon. After that, the rapid superplastic forming experiment of the left front side panel was carried out, and there were wrinkles at the upper end and the middle of front end, which was basically agreed with the results of the finite element analysis. In addition, after the forming process was improved,the left front side panel with good surface quality was successfully manufactured. Finally, the mechanical properties of material, the thickness distribution and the shape accuracy of part after forming were measured.

基金项目：

国家自然科学基金资助项目（51875122）；河南省自然科学基金资助项目（222300420254）

作者简介：杨代立（1988-），男，硕士，中级工程师,E-mail：yangdaili@njlew.cn;通信作者：王国峰（1973-），男，博士，教授,E-mail：gfwang@hit.edu.cn

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