郭江辉,张治民,郭为民,等.铝合金带法兰薄壁深锥筒件成形工艺研究[J].精密成形工程,2025,17(4):96-103.
GUO Jianghui,ZHANG Zhimin,GUO Weimin,et al.Forming Process of Aluminum Alloy Thin-walled Deep Conical Cylindrical Workpiece with Flange[J].Journal of Netshape Forming Engineering,2025,17(4):96-103. |
| 铝合金带法兰薄壁深锥筒件成形工艺研究 |
| Forming Process of Aluminum Alloy Thin-walled Deep Conical Cylindrical Workpiece with Flange |
| 投稿时间：2024-11-19 |
| DOI：10.3969/j.issn.1674-6457.2025.04.009 |
| 中文关键词: 薄壁锥筒件 法兰 塑性成形 数值模拟 等效应变 |
| 英文关键词: thin-walled conical cylindrical workpiece flange plastic forming numerical simulation equivalent strain |
| 基金项目:国家自然科学基金(52205427) |
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| 中文摘要: |
| 目的 针对带法兰薄壁深锥筒件中法兰与筒壁壁厚差大、筒体高度与直径比大导致的成形困难问题，开发一种制备带法兰薄壁深锥筒件的成形工艺。方法 在不同成形方案下进行Deform-3D有限元模拟，对比不同工艺成形过程中的金属流动规律，得到适合带法兰薄壁深锥筒构件的成形工艺，并对成形过程中的关键参数进行优化。最终进行试验试制，验证成形方案的可行性。结果 通过对比分析得出“预制法兰-复合挤压”成形工艺的成形效果最优，利用有限元模拟优化结构参数，得出当凸缘厚度H=40 mm、锥面上端圆角半径R=10 mm时，挤压件具有最合适的凸缘形状与应变均匀性，并在3 000 t压力机上成功试制。结论 由有限元模拟优化结果可知，与翻边工艺以及镦粗成形法兰工艺相比，“预制法兰-复合挤压”成形工艺显著降低了带法兰锥筒件成形过程中法兰部位的成形难度，同时实现了构件法兰部位凸缘形状的调控，降低了成形过程中的载荷。在3 000 t压力机上成形了筒壁直径430 mm、凸缘直径536 mm、凸缘厚度48 mm、挤压件高度1 350 mm的带法兰薄壁深锥筒件。 |
| 英文摘要: |
| In order to solve the problem that the thin-walled deep conical cylindrical workpiece with flange is difficult to form due to the large thickness difference between the flange and the cylinder wall and the large ratio of the height and diameter of the cylinder, the work aims to develop a forming process for preparing the thin-walled deep conical cylindrical workpiece with flange. Through the Deform-3D finite element simulation of different forming schemes, the metal flow law of different forming processes was compared, and the forming process suitable for the thin-walled deep conical cylindrical workpiece with flange was obtained, and the key parameters in the forming process were optimized. Finally, the test trial was carried out to verify the feasibility of the forming scheme. Through comparative analysis, it was concluded that the “prefabricated flange-composite extrusion” forming process had the best forming effect on the thin-walled deep conical cylindrical workpiece with flange. By optimizing the structural parameters by finite element simulation, it was concluded that the extruded workpiece had the most suitable flange shape and strain uniformity at the flange thickness H=40 mm and the fillet radius R=10 mm at the upper end of the cone surface, and was successfully trial-produced on a 3 000 t press. According to the finite element simulation optimization results, compared with the flanging process and the upsetting flange process, the “prefabricated flange-composite extrusion” forming process can significantly reduce the difficulty of forming the flange workpiece during the forming process of the conical cylindrical workpiece with flange, and can regulate the shape of the flange and reduce the load of the forming process. A flanged thin-walled deep conical cylindrical workpiece with a wall diameter of 430 mm, a flange diameter of 536 mm, a flange thickness of 48 mm and an extrusion height of 1 350 mm is formed on a 3 000 t press. |
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