陈明,刘鑫,徐勇,等.大截面变化率铝合金异形管整体液力成形工艺设计与优化[J].精密成形工程,2025,17(1):43-50.
CHEN Ming,LIU Xin,XU Yong,et al.Design and Optimization of the Whole Hydro-mechanical Forming Process of Aluminum Alloy Profile-shaped Tube with Large Cross-section Change Rate[J].Journal of Netshape Forming Engineering,2025,17(1):43-50. |
| 大截面变化率铝合金异形管整体液力成形工艺设计与优化 |
| Design and Optimization of the Whole Hydro-mechanical Forming Process of Aluminum Alloy Profile-shaped Tube with Large Cross-section Change Rate |
| 投稿时间：2024-05-31 |
| DOI：10.3969/j.issn.1674-6457.2025.01.006 |
| 中文关键词: 大截面变化率 管材液力成形 结构设计 正交试验 工艺优化 |
| 英文关键词: large cross-section change rate hydro-mechanical forming of tube orthogonal test structure design process optimization |
| 基金项目:沈阳市科技计划(22-301-1-10) |
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| 摘要点击次数: 48 |
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| 中文摘要: |
| 目的 针对某大截面变化率空心构件成形难的问题，采用液力成形的方法进行成形并对其生产工艺进行优化。方法 首先针对目标零件，通过压扁截面处对称及圆截面处对称2种不同的对称方式设计了A型结构和B型结构，通过有限元模拟对比了同一加载路径下2种不同结构的成形特点，选取了成形效果较好的A型结构进行成形工艺研究，建立了A型结构的成形分区图，继而根据成形分区图进行了正交试验设计。结果 在同一种加载路径下，A型结构成形的目标零件最大减薄率明显小于B型结构成形的目标零件最大减薄率，且在成形过程中，B型结构压扁特征处易出现褶皱或起皱趋势，而A型结构压扁特征处壁厚分布更加均匀，A型结构成形效果优于B型结构成形效果。优化后的工艺参数如下:压制压力为2 MPa、初始压力为7 MPa、成形压力为15 MPa、轴向进给为13 mm，成形零件最大减薄率为15.9%。结论 经成形分区图指导设计的正交成形试验结果均符合设计要求，成形分区图的设立对成形试验的设计具有指导作用;采用优化后的工艺参数获得了较好的试验效果，可为工业生产提供指导。 |
| 英文摘要: |
| To solve the difficulty of forming a hollow member with a large cross-section change rate, the work aims to form the hollow member with hydro-mechanical forming method and optimize the production process. Firstly, the A-type structure and B-type structure of the target part were designed by two different symmetrical modes of flattening section symmetry and circular section symmetry. The forming characteristics of the two different structures under the same loading path were compared by finite element simulation. The A-type structure with better forming effect was selected to study the forming process and the forming zoning diagram of the A-type structure was established. Then, the orthogonal test design was carried out according to the forming partition diagram. Under the same loading path, the maximum thinning rate of the target part formed by A-type structure was obviously smaller than that of B-type structure, and the tendency of folding or wrinkling was easy to appear at the flattening feature of B-type structure, while the wall thickness distribution was more uniform at the flattening feature of A-type structure, and the forming effect of A-type structure was better than that of B-type structure. The optimized process parameters were as follows:the pressing pressure of 2 MPa, the initial pressure of 7 MPa, the forming pressure of 15 MPa, the axial feed of 13 mm, and the maximum thinning rate of the formed parts of 15.9%. The results of the orthogonal forming test guided by the forming zone diagram meet the design requirements. The establishment of the forming zone diagram has a guiding role in the design of the forming test. The optimized process parameters are used to obtain good test results, which can provide guidance for industrial production. |
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