新型电冲击复合锻挤工艺对薄壁高筋构件成形质量的影响规律研究  

Effect of a New Type of Electroshock Composite Forging and Extrusion Process on Forming Quality of Thin-walled and High-rib Components

作　　者：宋燕利[1] 胡君豪 柳泽阳 陈龙[1] 李晔[1] 路珏[1] 刘艳雄[1] 刘煜键 魏勇波 苏建军 SONG Yanli;HU Junhao;LIU Zeyang;CHEN Long;LI Ye;LU Jue;LIU Yanxiong;LIU Yujian;WEI Yongbo;SU Jianjun(Hubei Provincial Key Laboratory of Modern Auto Parts Technology,Wuhan University of Technology,Wuhan 430070,China;Institute of Science and Art,University of Wales Trinity Saint David,Swansea SA18E,UK;Dongshi(Wuhan)Industrial Co.,Ltd.,Wuhan 430040,China;Hubei Qixing Automobile Body Co.,Ltd.,Hubei Suizhou 441300,China)

机构地区：[1]武汉理工大学现代汽车零部件技术湖北省重点实验室,武汉430070 [2]英国威尔士三一圣大卫大学科学与艺术学院,斯旺西SA18E,英国 [3]东实(武汉)实业有限公司,武汉430040 [4]湖北省齐星汽车车身股份有限公司,湖北随州441300

出　　处：《精密成形工程》2024年第12期241-252,共12页Journal of Netshape Forming Engineering

基　　金：国家自然科学基金(51975440);湖北省“楚天英才计划”;湖北省重点研发专项(2023BAB202);高等学校学科创新引智计划(B17034);教育部创新团队发展计划资助项目(IRT_17R83)。

摘　　要：目的为保证运载装备高功效轻量化的同时,提升其支撑防护结构的成形性能,提出一种铝合金薄壁高筋构件电冲击复合锻挤成形工艺方法,并探究模具下压量、电流密度对铝合金薄壁高筋构件成形质量的影响。方法通过DEFORM-3D仿真软件模拟分析2024-T4铝合金薄壁高筋构件电冲击复合锻挤下材料流动和填充规律,并对仿真分析结果进行电冲击复合锻挤成形试验验证。结果仿真模拟表明:随着模具下行,材料流动和填充难度增加,成形质量下降,不同电流密度对薄壁高筋构件成形影响程度不同。通过不同的电流密度进行试验,得到薄壁高筋构件最佳成形工艺。试验结果表明:当坯料预热至300℃,脉冲电流值为600 A时,成形后构件未见明显的开裂和填充不满等缺陷,成形的筋高提升35.14%,成形质量最好。结论与无电冲击的薄壁高筋构件相比,电冲击复合锻挤成形时构件整体成形性能提升,这是由于构件受脉冲电流焦耳热效应和非热效应的影响,金属流动性增强,成形载荷降低,更容易填充模具型腔。The work aims to a propose a composite forging and extrusion process method for aluminum alloy thin-walled and high-rib components and explore the effect of mold pressing and current density on the forming quality of aluminum alloy thin-walled and high-rib components,so as to ensure the high efficiency and lightweight of transportation equipment,and to im-prove the formability of its supporting and protective structures.By using DEFORM-3D simulation software,the material flow and filling rules of 2024-T4 aluminum alloy thin-walled and high-rib components under electroshock composite forging and ex-trusion were simulated and analyzed.Then,based on the simulation analysis results,electroshock composite forging and extrusion forming experiments were conducted to verify the results.Simulation results showed that as the mold descended,the difficulty of material flow and filling increased,and the forming quality decreased.Different current densities had varying degrees of effect on the forming of thin-walled and high-rib components.By conducting experiments with different current densities,the optimal forming process for thin-walled and high-rib components was obtained.The experimental results showed that when the blank was preheated to 300℃and the pulse current value was 600 A,there were no obvious cracks or insufficient filling defects in the formed components.The formed rib height increased by 35.14%,and the forming quality was the best.Compared with thin-walled and high-rib components without electroshock,the overall formability of the components is improved during electroshock composite forging and extrusion forming.This is because the components are affected by the Joule thermal effect and non-thermal effect of pulse current,which enhances the metal fluidity,reduces the forming load,and makes it easier to fill the mold cavity.

关 键 词：薄壁高筋构件 电冲击复合锻挤成形 2024-T4铝合金 DEFORM-3D仿真 锻挤试验 

分 类 号：TG312[金属学及工艺—金属压力加工]