高强铝合金车架纵梁内高压成形工艺及变形规律  

Internal high-pressure forming process and deformation law of high-strength aluminum alloy frame longitudinal beam

作　　者：孙康 胡志力[1,2] 龙曲波 庞秋[4] SUN Kang;HU Zhi-li;LONG Qu-bo;PANG Qiu(Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan University of Technology,Wuhan 430070,China;Hubei Collaborative Innovation Center for Automotive Components Technology,Wuhan University of Technology,Wuhan 430070,China;Dongfeng(Wuhan)Industrial Co.,Ltd.,Wuhan 430040,China;School of Mechanical and Electrical Engineering,Wuhan Donghu University,Wuhan 430212,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,湖北武汉430070 [2]武汉理工大学汽车零部件技术湖北省协同创新中心,湖北武汉430070 [3]东风(武汉)实业有限公司,湖北武汉430040 [4]武汉东湖学院机电工程学院,湖北武汉430212

出　　处：《塑性工程学报》2025年第3期90-98,共9页Journal of Plasticity Engineering

基　　金：湖北省重点研发计划项目(2021BAA200);湖北省自然科学基金资助项目(2021CFB523);湖北省科技重大项目(2022AAA001)。

摘　　要：为解决传统高强钢材料冲压焊接车架纵梁存在成形工序多、生产周期长、尺寸精度差和装配精度低的问题,提出了一种高强铝合金车架纵梁内高压成形工艺,以7075高强铝合金为材料,通过内高压成形制备车架纵梁,可以有效缩短生产周期,提升产品尺寸精度。基于Dynaform有限元软件对车架纵梁内高压成形进行仿真模拟,研究成形工艺参数对成形质量的影响,分析矩形截面过渡圆角区域的管壁填充行为。对车架纵梁进行试验试制,测量整体尺寸与壁厚分布,对纵梁不同区域的材料进行单向拉伸试验。最终发现在7075铝合金车架纵梁内高压成形过程中,轴向补料量20 mm,成形内压60 MPa,整形内压130 MPa时成形效果最好。对于过渡圆角的填充,管内压强越大、摩擦因数越小,填充效果越好,最终通过实验试制的纵梁长度为2000 mm,宽度为190 mm,高度为70 mm,过渡圆角半径为25 mm,减薄率为18%左右,工件屈服强度480 MPa,抗拉强度560 MPa,整体性能一致性好,尺寸精度更高,生产周期更短,说明7075铝合金通过内高压成形生产的车架纵梁可以满足实际生产的需要。To solve the problems of multiple forming processes,long production cycle,poor dimensional accuracy and low assembly accu-racy in traditional high-strength steel material stamping welding of frame longitudinal beams,an internal high-pressure forming process for high-strength aluminum alloy frame longitudinal beam was proposed.Taking 7075 high-strength aluminum alloy as the material,the frame longitudinal beams were prepared through internal high-pressure forming,which can effectively shorten the production cycle and improve product dimensional accuracy.Based on Dynaform finite element software,simulation of high-pressure forming inside the frame longitudi-nal beam was conducted to study the influence of forming process parameters on forming quality and to analyze the filling behavior of the pipe wall in the transition fillet area of the rectangular section.The frame longitudinal beam was experimentally trialed,the overall size and wall thickness distribution were measured,and the uniaxial tensile tests on materials in different areas of the longitudinal beam were carried out.It is ultimately found that during the internal high-pressure forming process of the high-strength aluminum alloy frame longitudinal beam,the best forming effect is achieved with the axial feeding amount of 20 mm,the forming internal pressure of 60 MPa,and the shaping internal pressure of 130 MPa.For the transition fillet filling,the greater the pressure inside the pipe and the lower the friction factor,the better the filling effect.Finally,the longitudinal beam with the length of 2000 mm,width of 190 mm,height of 70 mm filling,transition radius of 25 mm,thinning rate of about 18%,yield strength of 480 MPa,tensile strength of 560 MPa is pro-duced through experimental trial,and the overall performance consistency is good,the dimensional accuracy is higher,and the production cycle is shorter.It is indicated that the frame longitudinal beam produced by internal high-pressure forming of 7075 aluminum alloy can meet the needs of actual production.

关 键 词：7075铝合金 车架纵梁 内高压成形 圆角填充 

分 类 号：TG394[金属学及工艺—金属压力加工]