超声振动辅助T2紫铜薄板软模微胀形工艺研究  

Soft Die Micro Bulging Assisted by Ultrasonic Vibration Using T2 Copper Foil

作　　者：王春举 刘洋[2,3] 张志强[2] 程利冬 单德彬 郭斌 WANG Chun-ju;LIU Yang;ZHANG Zhi-qiang;CHENG Li-dong;SHAN De-bin;GUO Bin(Robotics and Microsystems Center,School of Mechanical and Electrical Engineering,Soochow University,Jiangsu Suzhou215131,China;School of Materials Science and Engineering,Harbin Institute of Technology,Harbin 150001,China;Col-lege of Physics and Electromechanical Engineering,Jishou University,Hunan Jishou 416000,China)

机构地区：[1]苏州大学机电工程学院机器人与微系统研究中心,江苏苏州215131 [2]哈尔滨工业大学材料科学与工程学院,哈尔滨150001 [3]吉首大学物理与机电工程学院,湖南吉首416000

出　　处：《精密成形工程》2023年第5期156-163,共8页Journal of Netshape Forming Engineering

基　　金：国家自然科学基金(51875128);国防基础科研项目(JCKY2020203B056);江苏省高等学校自然科学研究重大项目(20KJA460003);江苏省“六大人才高峰”高层次人才项目(GDZB-069);湖南省教育厅优秀青年项目(22B0539)。

摘　　要：目的解决薄板微胀形工艺中尺度效应导致的零件尺寸精度及形状精度不稳定以及板料减薄带来的成形极限下降等问题。方法对T2紫铜薄板进行多球冠微结构胀形工艺研究,对比刚模微胀形和超声振动辅助软模微胀形工艺条件下球冠微结构的成形质量,分析壁厚减薄率的变化规律,研究超声振动保压时间对球冠形貌及胀形高度的影响,对比分析紫铜薄板厚度对球冠胀形质量的影响规律。结果超声振动辅助软模微胀形工艺能够提高球冠微结构胀形极限,促进材料均匀变形,改善壁厚分布,相比于刚模微胀形,在超声作用下壁厚减薄率降低了约7%。超声振动保压时间越长,球冠贴模性越好,当保压时间为80 s时,球冠相对高度提升了0.1 mm。板料厚度越薄,成形极限越低,当板料厚度为100μm时,球冠成形质量及成形精度最高,在超声振动辅助软模微胀形工艺条件下,球冠成形极限进一步提高。结论超声振动与软模相结合的复合成形方法能够降低T2紫铜薄板微胀形尺度效应的不利影响,抑制壁厚过度减薄,显著提升胀形精度和成形极限。The work aims to solve the unstable dimensional accuracy and shape accuracy of parts caused by size effect in micro bulging process of foils and the reduction of forming limit caused by thinning of foils.In this work,micro bulging process of multi-spherical cap structure for T2 copper foil was researched.By the comparison between rigid die bulging and ultrasonic vibration assisted soft die micro bulging,the change of forming quality and wall thickness reduction rate was studied.The effects of ultrasonic holding time on spherical cap morphology and bulging height were discussed.The effects of wall thickness of copper foils on bulging quality were compared and analyzed.The results showed that the micro bulging process combining ultrasonic vibration and soft die could increase the bulging limit of spherical cap,promote deformation uniformity and improve wall thickness distribution.Compared with rigid die micro bulging,the thinning ratio was decreased by 7%under the effects of ultrasonic vibration.The fitness increased with the increase of ultrasonic holding time.The relative height of spherical cap was increased by 0.1 mm when the holding time was 80 s.The bulging limit decreased with the decrease of wall thickness.The forming quality and accuracy were the best when the wall thickness was 100μm.The bulging limit can be further improved during ultrasonic vibration assisted soft die micro bulging process.The forming method combining ultrasonic vibration and soft die can decrease the negative size effect,inhibit the excessive thinning in micro bulging of T2 copper foils and effectively improve the bulging accuracy and forming limit.

关 键 词：超声振动 球冠 软模 微胀形 紫铜薄板 

分 类 号：TG306[金属学及工艺—金属压力加工]