复杂曲率铝合金薄壁构件气胀成形技术研究  

Study on gas forming technology for complex curvature aluminum alloy thin-walled components

作　　者：赵忠浩 赵喜东 亓昌 盈亮 同勃阳 杨姝[1,2] 魏文涛 ZHAO Zhonghao;ZHAO Xidong;QI Chang;YING Liang;TONG Boyang;YANG Shu;WEI Wentao(School of Mechanical Engineering,Dalian University of Technology,Dalian 116024,China;Ningbo Institute of Dalian University of Technology,Ningbo 315016,China;Academy of China Changfeng Electro-Mechanical Technology,Beijing 100854,China)

机构地区：[1]大连理工大学机械工程学院,辽宁大连116024 [2]大连理工大学宁波研究院,浙江宁波315016 [3]中国长峰机电技术研究设计院,北京100854

出　　处：《重庆理工大学学报（自然科学）》2024年第6期109-117,共9页Journal of Chongqing University of Technology：Natural Science

基　　金：国家重点研发计划课题(2022YFB2503503)。

摘　　要：为满足复杂曲率轻量化薄壁构件快速高质量成形的需求,对5754铝合金复杂构件的气胀成形性能进行了试验与仿真研究。通过单一变量法确定了型腔气压和压边力的最佳工艺参数。结合数值模拟和成形试验,分析研究了型腔气压和压边力对构件成形性能的影响规律及成形机理。结果表明,最佳的成形气压和压边力分别为1.2 MPa和4.6 MPa。当气压小于1 MPa时,最大成形深度不断增加,最大应力位于主特征中心,壁厚分布由中心向两侧递增;当气压超过1 MPa后,最大成形深度保持不变,最大应力位于型腔中心两侧,壁厚分布由中心向两侧先减后增。当压边力小于4.3 MPa时会导致构件边缘起皱;增大压边力可有效抑制起皱,但压边力超过4.9 MPa时会增加构件局部破裂的风险。因此,采用上述最佳工艺参数能够成形质量良好的复杂曲率铝合金薄壁构件。With the progress and development of science and technology,the demand for industrial alloy integral thin-wall components with light weight,high strength,large size and complex shape is increasing,and the manufacturing process also has higher requirements.Because of its good plasticity and relatively low price,aluminum alloy has become an ideal material for the manufacture of parts for carrying equipment.To meet the demands of rapid and high-quality forming for lightweight thin-wall components with complex curvature,5754 thin-walled aluminum alloy members with large depth-to-diameter ratio and complex curvature characteristics are taken as the research object in this study,which employs advanced gas forming technology to experimentally and numerically investigate the forming performance of 5754 aluminum alloy complex components.Firstly,a self-designed rapid gas forming platform for sheet metal is established to conduct gas forming experiments on thin-walled components made of 5754 aluminum alloy with complex curvature.The optimal values for cavity air pressure and blank edge holding force are determined through single-variable method.Secondly,a finite element model for the gas forming of aluminum alloy thin-walled components is established using LS-DYNA software.The forming process and quality of complex-curvature thin-walled aluminum alloy components under various process parameters are examined.Finally,combining numerical simulation with experimental result data,the forming depth,wall thickness distribution,and maximum stress and strain of the sample are used as forming performance characterization parameters,and a parameter analysis is conducted to study the effects and mechanisms of cavity air pressure and blank holding force on forming performance.The results show that,in the case studied,the minimum cavity pressure required for mold sticking is 1 MPa.When the cavity air pressure is less than 1 MPa,the maximum forming depth continuously increases.The maximum stress and strain are located at the center of the

关 键 词：5754铝合金 薄壁构件 气胀成形 工艺参数 数值模拟 

分 类 号：U465[一般工业技术—材料科学与工程]