3003Al-H14薄壁微小通道扁管波形冲压成形尺寸对截面变形的作用规律  

Effect of Forming Size on Sectional Deformation of Wave Stamping of 3003Al-H14 Micro Channel Flat Tube

作　　者：程传峰 金明 王项如 朱英霞[3] 程一峰 盘朝奉[4] 王园[3] CHENG Chuanfeng;JIN Ming;WANG Xiangru;ZHU Yingxia;CHENG Yifeng;PAN Chaofeng;WANG Yuan(ANHUI XMAX New Energy Technology Co.,Ltd.,Anqing 246001,China;ANHUI ARN GROUP Co.,Ltd.,Anqing 246001,China;School of Mechanical Engineering,Jiangsu University,Zhenjiang 212013,China;Automotive Engineering Research Institute,Jiangsu University,Zhenjiang 212013,China)

机构地区：[1]安徽新富新能源科技股份有限公司,安徽安庆246001 [2]安徽环新集团股份有限公司,安徽安庆246001 [3]江苏大学机械工程学院,江苏镇江212013 [4]江苏大学汽车工程研究院,江苏镇江212013

出　　处：《中国材料进展》2024年第3期265-272,共8页Materials China

基　　金：国家自然科学基金项目(51601070,51875263);江苏省自然科学基金项目(BK20181447)。

摘　　要：薄壁微小通道波形扁管是建设新能源汽车锂电池组恒温系统的绝佳材料,成形尺寸是影响其冲压成形截面变形的关键因素。建立了实验验证的3003Al-H14微小通道薄壁扁管的波形冲压-回弹有限元模型。基于所建模型,研究了截面高度、管坯壁厚、内外面相对弯曲半径缩放系数等成形尺寸,对截面变形率和平均截面变形率的作用规律。研究发现:①横截面上边缘孔的截面变形率通常较大,其余孔的截面变形率相对较小且大小一致;纵截面上孔的截面变形率呈现波峰波谷高、中间段低的分布特点。②扁管的截面变形率随着截面高度增大而增大,当截面高度超过4 mm时,扁管内的筋显著弯折,横截面塌陷严重。③扁管的平均截面变形率随着壁厚增大呈指数函数下降;当壁厚等于0.1 mm时,所有截面都畸变严重,而当壁厚超过0.3 mm时,最大截面畸变率下降至24.71%。④内外面相对弯曲半径的缩放系数越大,则内外面的实际弯曲程度越小,平均截面变形率也越小。研究成果对薄壁微小通道波形扁管的精确成形具有科学意义和工程价值。The thin-walled flat tube with microchannels is an essential component for the construction of the constant temperature system in lithium-ion battery packs for new energy vehicles.The dimensions used in forming this component are critical factors that influence the deformation of the stamped section.An experimentally verified finite element model has been developed for the waveform stamping-springback of 3003Al-H14 thin-walled flat tubes with microchannels.This model was used to investigate the impact of forming dimensions such as section height,tube blank wall thickness,and relative bending radius scaling factors of the inner and outer surfaces on the section deformation ratio and average section deformation ratio.The research findings are as follows:①The section deformation ratio of the holes at the upper edge of the cross-section is generally larger,while the deformation ratio of the remaining holes is relatively small and consistent in size.The section deformation ratio of the holes on the longitudinal section exhibits a distribution pattern with high peaks and valleys and low values in the middle section.②The section deformation ratio of the flat tube increases with the increase in section height.When the section height exceeds 4 mm,the ribs inside the flat tube significantly bend,leading to severe collapse of the cross-section.③The average section deformation ratio of the flat tube decreases exponentially with increasing wall thickness.When the wall thickness equals 0.1 mm,all sections exhibit severe distortion,while when the wall thickness exceeds 0.3 mm,the maximum section distortion ratio decreases to 24.71%.④A larger scaling factor of the relative bending radius of the inner and outer surfaces results in a smaller actual bending degree of these surfaces and a smaller average section deformation ratio.This study has scientific significance and engineering value for the precise forming of thin-walled microchannel waveform flat tubes.

关 键 词：微小通道管 冲压 薄壁件 成形尺寸 截面变形 

分 类 号：TG386[金属学及工艺—金属压力加工]