大型薄壁曲面铝合金零件的电磁渐进-拉形(EMIF-SF)成形技术  

Electromagnetic incremental forming combined with stretch forming technology for large-scale and thin-walled aluminum alloy sheet

作　　者：张志武 崔晓辉 黄长清 肖小亭[3] 李建军[4] 莫健华[4] Zhang Zhiwu;Cui Xiaohui;Huang Changqing;Xiao Xiaoting;Li Jianjun;Mo Jianhua(Light Alloy Research Institute,Central South University,Changsha 410083 ,China;College of Mechanical and Electrical Engineering,Central South University,Changsha 410083 ,China;School of Material and Energy,Guangdong University of Technology,Guangzhou 510006,China;State Key Laboratory of Material Processing and Die & Mould Technology,Huazhong University of Science and Technology,Wuhan 430074 ,China)

机构地区：[1]中南大学轻合金研究院,湖南长沙410083 [2]中南大学机电工程学院,湖南长沙410083 [3]广东工业大学材料与能源学院,广东广州510006 [4]华中科技大学材料成形与模具技术国家重点实验室,湖北武汉430074

出　　处：《锻压技术》2019年第3期41-49,共9页Forging & Stamping Technology

基　　金：国家自然科学基金资助项目(51775563;51405173);广州市科技计划项目(201707010472);中南大学高性能复杂制造国家重点实验室(ZZYJKT2017-03);中南大学研究生自主探索创新项目(502211810);华中科技大学材料成形与模具技术国家重点实验室开放课题研究基金(P2017-013)

摘　　要：将电磁脉冲渐进成形(EMIF)和传统拉形(SF)技术结合在一起,形成一种新颖的板材复合成形方法,实现了大型薄壁曲面铝合金零件的精确制造。建立了适合该成形方法的3D有限元模型,分析了线圈结构、线圈个数、线圈移动轨迹和压板尺寸以及不同尺寸压板组合对零件最终成形质量的影响。根据模拟结果,采用双腰形线圈对称放电解决材料变形不均匀的问题,采用小放电能量(<9. 6 kJ)和小型工装(台面尺寸为1. 4 m×1. 4 m)搭建了实验平台,最终线圈经过放电86次,拉形11次,得到直径近Φ700 mm、高度150 mm的铝合金椭球形零件。研究表明:和旋压成形相比,此方法能够明显抑制壁厚减薄;和传统冲压相比,此方法能够明显抑制起皱。Combining electromagnetic incremental forming( EMIF) with traditional stretch forming( SF) technology,a novel composite forming method for sheet metal was developed,which realized the precise manufacturing of large thin-walled surface aluminum alloy parts.Then,a 3D simulation model was established,and the influences of coil structure,the number of coils,coils moving path,dimension of pressing plate and combination of different sizes of pressing plate on the final forming quality were analyzed. According to the simulation results,the problem of non-uniform deformation of materials was solved by symmetrical discharge of double-waist coil,and the experimental platform was built with small discharge energy(< 9. 6 kJ) and small tooling( table size is 1. 4 m × 1. 4 m). Finally,the coil was discharged 86 times and stretched eleven times,and the aluminum alloy ellipsoidal parts were obtained with diameter Φ700 mm and height 150 mm. The results show that comparing with spinning,the new method can obviously inhibit the wall thickness reduction,and comparing with traditional stamping,the new method can greatly inhibit wrinkle.

关 键 词：电磁渐进成形 复合成形 大尺寸薄壁零件 双腰形线圈 多次放电 

分 类 号：TG391[金属学及工艺—金属压力加工]