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| 大口径铝合金波纹管电磁胀形数值模拟 |
| Numerical Simulation of Electromagnetic Bulging of Large Diameter Aluminum Alloy Bellows |
| Received:May 05, 2016 Revised:July 10, 2016 |
| DOI：10.3969/j.issn.1674-6457.2016.04.001 |
| 中文关键词: 大口径铝合金波纹管 电磁胀形 贴模性 数值模拟 |
| 英文关键词: large diameter aluminum alloy bellows electromagnetic bulging fittability numerical simulation |
| 基金项目:国家重点基础研究发展计划（973）（2011CB012802）；国家自然科学基金（51575206）； 中国航天科技集团公司航天科技创新基金（CASC150704） |
| Author Name | Affiliation | | HONG Xiu-dong | State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering,Huazhong University of Science and Technology, Wuhan 430074, China | | HUANG Liang | State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering,Huazhong University of Science and Technology, Wuhan 430074, China | | LI Jian-jun | State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering,Huazhong University of Science and Technology, Wuhan 430074, China | | MA Fei | Changzheng Machinery Factory, China Aerospace Science and Technology Corporation, Chengdu 610100, China | | LIN Lei | Changzheng Machinery Factory, China Aerospace Science and Technology Corporation, Chengdu 610100, China |
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| 中文摘要: |
| 目的 研究大口径铝合金波纹管电磁成形过程及工艺参数对成形效果的影响规律。 方法 针对波纹管现有制造工艺——压弯和焊接复合成形存在压痕严重、焊缝多和可靠性不高等问题，提出采用电磁成形波纹管的方法，并基于 ANSYS 建立了波纹管电磁胀形的三维有限元分析模型。 结果 揭示了波纹管电磁胀形过程中的应力应变分布规律，发现波纹区域和过渡圆角区域是应力和应变集中区。采用单因素实验方法，获得了放电电压和线圈匝数对成形质量的影响规律。 结论 在波纹管电磁胀形过程中，波纹区域的应力和应变均呈圆环带状分布，波纹管的壁厚在波纹的波峰处达到最小，最大减薄率为10.67%。放电电压和线圈匝数都存在一个最佳值。放电电压过小时，成形不足，放电电压过大时，工件高速碰撞模具，引起较大反弹，导致最终贴模性较差；线圈匝数也对成形质量有一定的影响，在本次模拟实验中， 11 匝线圈作用下的工件贴模性最佳。 |
| 英文摘要: |
| To study electromagnetic forming of large diameter aluminum alloy bellows and the influence of processing parameters, a method for electromagnetic shaping bellows was proposed with respect to the problems such as severe indentation, too much welding seams and poor reliability of current bellows in the manufacturing process---bending and welding composite forming, and a three dimensional finite element analysis model of electromagnetic forming of bellows was established based on the ANSYS. By revealing the distribution law of stress and strain in electromagnetic bulging of bellows, the study showed that the wave region and the transition fillet region were stress and strain concentration zone. The influence of discharge voltage and coil turns on the forming quality was obtained by single factor experimental design method. In the electromagnetic bulging of bellows, the stress and strain of the corrugated area are distributed in circular ring, and the wall thickness of bellows reaches the minimum at the crest of the wave, the maximum thinning rate is 10.67%. There is an optimal value of the discharge voltage and the number of turns of the coil. The forming is sufficient when discharge voltage is too small; when the discharge voltage is too large, the workpiece impacts die with high speed, causing large rebound and resulting in poor fittability; The number of turns of the coil also has a certain influence on the forming quality. In this experiment, the fittability is the best under 11 turns of coil. |
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