工业级5083铝合金市域车车门正反胀超塑性成形工艺  

Direct-reverse bulging superplastic forming process of urban railway door of industrial 5083 aluminum alloy

作　　者：梁继业 杜志豪 林海朋 王国峰[3,4] LIANG Ji-ye;DU Zhi-hao;LIN Hai-peng;WANG Guo-feng(Changchun Railway Vehicles Co.,Ltd.,Changchun 130000,China;School of Mechanical and Electric Engineering,Nanyang Normal University,Nanyang 473061,China;School of Materials Science and Engineering,Harbin Institute of Technology,Harbin 150001,China;National Key Laboratory for Precision Hot Processing of Metals,Harbin Institute of Technology,Harbin 150001,China)

机构地区：[1]中车长春轨道客车股份有限公司,吉林长春130000 [2]南阳师范学院机电工程学院,河南南阳473061 [3]哈尔滨工业大学材料科学与工程学院,黑龙江哈尔滨150001 [4]哈尔滨工业大学金属精密热加工国防重点实验室,黑龙江哈尔滨150001

出　　处：《塑性工程学报》2022年第1期66-72,共7页Journal of Plasticity Engineering

基　　金：国家自然科学基金资助项目(51875122)。

摘　　要：以工业级5083铝合金为研究对象,对市域车车门的铝合金外壁板的正反胀超塑性成形工艺进行了研究。对工业级5083铝合金在400~560℃,应变速率5×10^(-4)~5×10^(-3)s^(-1)下的单轴拉伸试验进行了研究,结果表明:工业级5083铝合金具有较好的高温伸长率,在480℃和10^(-3)s^(-1)条件下,最大伸长率为242%。基于高温拉伸得到的应力-应变曲线,构建了5083铝合金超塑性成形本构模型。设计了带嵌环的正反胀超塑成形凸模和凹模,通过嵌环与凸模或凹模的配合,可以实现一套模具完成左、右两侧车门的正反胀超塑成形。利用MSC.MARC软件对市域车左侧车门外壁板的正反胀超塑成形工艺进行有限元分析,选择合适的正反胀时间和压力,最薄部位位于窄侧把手与门框之间,最小厚度为2.56 mm。最后进行了左侧车门外壁板的正反胀超塑成形试验,成功地制造了表面质量良好、型面精度满足要求的左侧车门外壁板。外壁板最小厚度2.69 mm,最大减薄率为32.75%,出现在窄侧把手与门框相接位置,与模拟结果相一致。Taking industrial 5083 aluminum alloy as the research object,the direct-reverse superplastic forming process of aluminum alloy outer wallboard of urban railway door was investigated.The uniaxial tensile test of industrial 5083 aluminum alloy at 400-560 ℃ with the strain rate of 5×10^(-4)-5×10^(-3) was carried out.The results show that the industrial 5083 aluminum alloy has good high-temperature elongation,and the maximum elongation is 242% at 480 ℃ with 10^(-3) s^(-1).The constitutive model of 5083 aluminum alloy superplastic forming was constructed based on the stress-strain curves obtained by high-temperature tensile test.The punch and die with inserted ring applied for the direct-reverse bulging superplastic forming process were designed,and the left and right sides doors could be superplastic formed through a set of dies by matching the instered ring with punch and die.Then the finite element simulation was conducted on direct-reverse bulging superplastic forming experiment for outer wallboard of left side urban railway door by the MSC.MARC software,and with the appropriate direct-reverse bulging time and pressure,the minimum thickness is 2.56 mm which takes place at the part between the handrail and the doorframe.Finally,the direct-reverse superplastic forming process of the outer wallboard was carried out,and the outer wallboard of left side door with high accuracy and good surface quality was successfully manufactured.The minimum thickness is 2.69 mm and the maximum thickness thinning rate is 32.75%,and it takes place at the part between the handrail and the doorframe,which is consistent with the result of finite element simulation.

关 键 词：5083铝合金 超塑成形 市域车车门 有限元模拟 

分 类 号：TG304[金属学及工艺—金属压力加工]