复杂异形空心构件协同变载液压成形技术  

Hydroforming Technology of Complex Special-shaped Hollow Components by Collaborative and Variable Loadings

作　　者：崔晓磊[1,2] 贺久强 韩聪[1,2] 苑世剑[1,2] CUI Xiaolei;HE Jiuqiang;HAN Cong;YUAN Shijian(National Key Laboratory for Precision Hot Processing of Metals,Harbin Institute of Technology,Harbin 150001;School of Materials Science and Engineering,Harbin Institute of Technology,Harbin 150001)

机构地区：[1]哈尔滨工业大学金属精密热加工国家级重点实验室,哈尔滨150001 [2]哈尔滨工业大学材料科学与工程学院,哈尔滨150001

出　　处：《机械工程学报》2023年第20期143-153,共11页Journal of Mechanical Engineering

摘　　要：管坯液压成形是制造复杂异形空心构件的先进成形技术,对于提升汽车轻量化水平、实现节能减排具有重要意义。针对现有恒压加载液压成形技术存在构件尺寸分散大、废品率高和模具变形严重的难题,发明了基于液体压力-体积协同变载精确成形工艺,提出通过控制高压液体体积调控模具弹性变形量和构件尺寸精度,尺寸精度比传统压力加载法提高1倍多;提出了合模力随内压全量程可变加载技术,大幅减小模具尺寸,且使模具变形量降到恒定合模力条件下模具变形量的1/3以下;突破双腔内压与多工艺参量协同加载控制技术,实现了双套系统并联成形,生产效率提高近1倍,满足了新能源汽车对高品质、高效率和低成本生产的要求,提升我国汽车关键构件的制造水平。最后,对协同变载液压成形技术的未来研究重点与发展方向进行了展望。Tube hydroforming is an advanced forming technology for manufacturing complex special-shaped hollow components,which is of great significance for improving the lightweight level of automobiles and realizing energy saving and emission reduction.To solve the problem of large size dispersion,a high rejection rate of components,and severe deformation of die in traditional hydroforming technology based on constant pressure and clamping force loading,a precision hydroforming process was first developed by collaborative and variable loadings of liquid pressure and volume.It is proposed to control elastic deformation of the die and dimensional accuracy of the component by controlling the volume of high-pressure liquid injected into the tube blank.The dimensional accuracy is more than 1 times higher than that of the traditional pressure loading method.Moreover,a variable loading technology of clamping force was proposed to vary with internal pressure in the whole process,which greatly reduces the size of the die and reduces its deformation to less than 1/3 of the die deformation under constant clamping force.Furthermore,a control technology was broken through to improve equipment compatibility and production efficiency for coupled collaborative loading of double-cavity pressures and multiple process parameters.In this case,a parallel connection of two hydroforming systems is realized,and the production efficiency is nearly doubled.The demand for high quality,high efficiency,and low-cost production of new energy vehicles can be satisfied using this hydroforming technology,which can upgrade the manufacturing level of key automotive components in our country.Finally,the future research focus and development direction of hydroforming technology by collaborative and variable loadings are prospected.

关 键 词：异形空心构件 液压成形 压力-体积协同加载 可变合模力 

分 类 号：TG394[金属学及工艺—金属压力加工]