基于响应面法的带交叉筋筒形零件热摆辗成形质量分析  

Quality analysis on hot orbital forming for cylindrical parts with cross ribs based on response surface method

作　　者：吴磊[1] 冯玮[1,2,3] Wu Lei;Feng Wei(School of Materials Science and Engineering,Wuhan University of Technology,Wuhan 430070,China;Hubei Material Green Precision Forming Engineering Technology Research Center,Wuhan 430070,China;Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan 430070,China)

机构地区：[1]武汉理工大学材料科学与工程学院,湖北武汉430070 [2]湖北省材料绿色精密成形工程技术研究中心,湖北武汉430070 [3]现代汽车零部件技术湖北省重点实验室,湖北武汉430070

出　　处：《锻压技术》2022年第9期118-125,共8页Forging & Stamping Technology

基　　金：高等学校学科创新引智计划资助项目(B17034);教育部创新团队发展计划项目(IRT_17R83)。

摘　　要：为了研究铝合金带交叉筋筒形零件热摆辗成形过程中交叉筋的几何参数对筋部充填不满、折叠等成形质量问题的影响规律,以交叉筋的宽度和高度为变量,采用Box-Behnke设计(BBD)方法进行了试验设计,利用有限元方法模拟了具有不同筋高和筋宽的筒形零件的热摆辗成形过程,计算了成形结束时不同筋高和筋宽时筋部的充填质量和折叠率,建立了以交叉筋的宽度和高度为设计变量,以筋部的充填质量和折叠率为目标的二次多项式响应面模型。结合响应面模型和有限元方法,得到了不同筋宽和筋高下零件的成形质量,预测了成形质量最佳时交叉筋的高度和宽度,利用有限元对预测结果进行了模拟和验证。结果表明:当高筋的高宽比小于6时,筋部的充填质量较好;随着筋宽的增加,折叠率逐渐减小;优化后零件的筋部充填完整,折叠缺陷极少,模拟结果与预测结果一致,验证了响应面模型的准确性。In order to study the influence laws of geometric parameters for cross ribs on the forming quality problems of rib insufficient filling, folding and so on during the hot orbital forming process of aluminum alloy cylindrical part with cross ribs, taking the width and height of cross ribs as variables, the experimental design was carried out by Box-Behnke designing(BBD) method, and the hot orbital forming process of cylindrical parts with different rib widths and rib heights was simulated by the finite element method. Then, the filling quality and folding rate of ribs with different rib widths and rib heights at the end of forming were calculated, and taking the width and height of cross ribs as the design variables and the filling quality and folding rate of ribs as the objectives, a quadratic polynomial response surface model(RSM) was established. Furthermore, the forming quality of part with different rib width and rib heights was obtained by combining response surface model and finite element method, and the height and width of cross rib when the forming quality was the best were predicted, which were simulated and verified by finite element. The results show that the filling quality of ribs is better when the height-width ratio of high ribs is less than six, and the folding rate decreases gradually with the increasing of the rib width. After optimization, the ribs of part are filled fully, the fold defects are few, and the simulation results are consistent with the prediction results to verify the accuracy of the response surface model.

关 键 词：铝合金 交叉筋筒形零件 热摆辗成形 响应面模型 充填质量 折叠率 

分 类 号：TG306[金属学及工艺—金属压力加工]