大规格泡沫铝锭成型模具轻量化设计  

Lightweight Design of Large Size Foamed Aluminum Ingot Molding Mold

作　　者：洪小英[1,2] 彭海军 杨勇福 周杰 彭世鑫[3] HONG Xiaoying;PENG Haijun;YANG Yongfu;ZHOU Jie;PENG Shixin(Institute of Modern Manufacturing,Sichuan Vocational College of Information Technology,Sichuan Guangyuan 611730,China;College of Materials Science and Engineering,Chongqing University,Chongqing 400044,China;Chongqing Jie Pin Technology Co.,Ltd.,Chongqing 401329,China)

机构地区：[1]四川信息职业技术学院现代制造学院,四川广元611730 [2]重庆大学材料科学与工程学院,重庆400044 [3]重庆杰品科技股份有限公司,重庆401329

出　　处：《精密成形工程》2024年第8期148-154,共7页Journal of Netshape Forming Engineering

基　　金：广元市2023科技支撑计划(23ZDYF0096)。

摘　　要：目的解决大规格泡沫铝模具(尺寸2800 mm×1000 mm×X mm)在成型过程中因极易发生塑性变形导致模具失效而造成模具寿命低、模具成本偏高的问题。方法基于数字模拟方法,实现模具轻量化设计。首先分析了泡沫铝模具的工作过程,确定了泡沫铝模具变形过程主要产生阶段;其次采用热弹塑性有限元法建立了泡沫铝模具冷却过程的有限元模型,得到了泡沫铝模具冷却过程,分别分析了冷却40、560、1330和4200 s时的温度场、最大塑性主应变场及位移场的分布情况和泡沫铝模具冷却过程中的变化规律,最后将模拟结果与实际的模具变形情况进行对比,泡沫铝模具变形方式与模拟情况基本吻合,再结合模拟轻量化模具结构,将模具用于实际验证。结果泡沫铝模具变形的主要原因为泡沫铝模具各部分冷却不均匀,导致其温度梯度大的地方产生了少量塑性变形。结论大规格泡沫铝锭成型模具可以通过优化模具结构、减轻模具重量来实现模具成本的降低。The work aims to solve the problem that large foam aluminum molds(molds with dimensions greater than 2800 mm×1000 mm×X mm)are prone to deformation during the molding process,which leads to mold failure,resulting in extremely low service life and high mold cost.In this paper,lightweight design of molds was achieved based on the digital simulation method.Firstly,the working process of aluminum foam molds was analyzed,the main generation stage of aluminum foam mold defor-mation was found;Then the finite element model of the aluminum foam mold cooling process was established by thermos elas-toplastic finite element method.By obtaining the cooling process of the aluminum foam molds,the distribution of temperature field,maximum plastic strain field,and displacement field at different stages of cooling(40,560,1330,and 4200 s)was ana-lyzed.Then the simulation results were compared with the actual mold deformation situation.The deformation mode of the foam aluminum mold was consistent with the simulation.Combined with the simulation of the lightweight mold structure,the mold production and processing were used for practical verification.The study showed that the main reason for the deformation of the aluminum foam mold was that the cooling of each part of the aluminum foam mold was not uniform,which lead to a small amount of plastic deformation in the place where the temperature gradient was large.In conclusion,large size foam aluminum ingot molds can optimize the mold structure,and it is feasible to reduce the mold cost by reducing the mold weight.

关 键 词：泡沫铝 模具 温度场 应变场 位移场 

分 类 号：TG14[一般工业技术—材料科学与工程]