5A02铝合金薄壁异形管内高压成形数值模拟及试验  

Numerical Simulation and Experiment of Internal High Pressure Forming(IHPF) of 5A02 Aluminum Alloy Thin-Walled Shaped Tubes

作　　者：靳舜尧[1] 唐振宇 黄重国[1] Jin Shunyao;Tang Zhenyu;Huang Zhongguo(School cf Mechanical Engineerings University of Science and Technology Beijing,Beijing 100083,China)

机构地区：[1]北京科技大学机械工程学院,北京100083

出　　处：《稀有金属》2020年第11期1121-1128,共8页Chinese Journal of Rare Metals

基　　金：教育部基本科研项目(FRF-TP-19-013A2)资助。

摘　　要：利用有限元分析软件Pam-stamp,对5A02铝合金薄壁异形管的内高压成形(IHPF)过程进行数值模拟,研究管坯危险截面的贴模过程和变形机制,优化内压-补偿加载路径,并进行多次试验验证。结果表明,内高压成形过程中管坯曲率半径大的区域先贴合模具,曲率半径小的区域后贴合,后贴合区域会出现由于壁厚减薄严重甚至开裂的情况;不同加载路径的模拟结果表明,在成形过程中位移补偿与加载压力配合不合理会造成管件的褶皱或破裂,优化位移补偿可避免冲击式变形和过多位移堆积,防止壁厚减薄严重和壁厚增厚。多次的数值模拟和实际试验结果基本吻合,两者在危险截面处的壁厚分布变化趋势一致,验证了内高压成形过程位移补偿能够有效地对管坯成形区补料,利于变形过程中管坯材料均匀流动,从而控制壁厚减薄率;试验结果表明,优化的r6路径是合理可行的,可有效指导异形管的内高压成形过程。The internal high pressure forming(IHPF)of 5 A02 aluminum alloy thin-walled shaped tube was conducted using finite element analysis software Pam-stamp. The process of fitting the die and deformation mechanism of the dangerous section was studied through numerical simulation,the loading path of internal pressure and feeding was optimized and verified through experiment. The results showed that the area with a large radius of curvature fitted the die firstly during internal high pressure forming process,and then the area with a small radius of curvature was attached. The wall thickness of the area fitted to the die finally was severely thinned even cracked. The numerical simulation results of different loading paths showed that the improper matching of internal pressure and feeding in the forming process caused the tube to fold or break. The optimized feeding could avoid the impact deformation and excessive displacement accumulation,to prevent the severe thinning of the wall thickness and excessive material filling of the tube wall. The numerical simulation results and the actual experiment results were basically consistent,and the variation trend of the wall thickness distribution at the dangerous section was consistent. It was verified that the feeding in the IHPF process could effectively supplement the material in the forming area of the tube fitting,which was conducive to the uniform flow of the material in the deformation process,so as to control the thinning rate of the wall thickness. The experiment results showed that the optimized r6 path was reasonable and feasible,and could be effectively referenced by the process of IHPF of the shaped tube.

关 键 词：Pam-stamp 异形管 内高压成形(IHPF) 数值模拟 

分 类 号：TG394[金属学及工艺—金属压力加工]