高筋薄板件往复包络成形工艺设计及塑性成形规律  

Design Method and Plastic Forming Law of Reciprocating Envelope Forming Process for Thin Plates with High Ribs

作　　者：邱春璐 庄武豪 韩星会[1,2] QIU Chunlu;ZHUANG Wuhao;HAN Xinghui(School of Automotive Engineering,Wuhan University of Technology,Wuhan 430070,China;Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan 430070,China)

机构地区：[1]武汉理工大学汽车工程学院,武汉430070 [2]现代汽车零部件技术湖北省重点实验室,武汉430070

出　　处：《精密成形工程》2025年第4期61-69,共9页Journal of Netshape Forming Engineering

基　　金：国家自然科学基金(U21A20131,52005375);教育部创新团队发展计划(IRT17R83)。

摘　　要：目的针对现有包络成形工艺中包络模具仅作单向包络运动,导致金属分配不协调,容易出现高筋生长不一致和塑性变形不均匀等问题,提出了一种高筋薄板件往复包络成形新工艺。方法采用有限元模拟仿真方法,对比分析了单向包络和往复包络2种工艺方案下高筋薄板件的金属流动特性、高筋生长情况、金属流线形态及等效应变演变规律,并采用物理试验验证所提出的高筋薄板件往复包络成形工艺的有效性。结果与单向包络成形相比,往复包络成形中金属作顺时针-逆时针交替流动,减弱了金属单一周向流动趋势,使金属分配更协调,提升了筋高均匀性。往复包络成形能够获得沿高筋薄板件轮廓分布的连续金属流线,并且金属流线不发生扭转。此外,由包络模具往复包络成形的高筋型面等效应变大于下模整体约束成形的非高筋型面等效应变,且等效应变分布较单向包络成形的更均匀。采用物理试验获得了筋高分布均匀的高筋薄板件,且试验样件与仿真样件的几何形状十分相似。结论采用往复包络成形能够获得金属分配合理、金属流线连续、筋高和塑性变形分布均匀的高筋薄板件。The work aims to propose a novel reciprocating envelope forming process for thin plates with high ribs(TPHR)to solve problems such as uneven metal distribution,inconsistent rib growth,and non-uniform plastic deformation due to the unidirectional envelope motion.Using finite element simulation,this study comparatively analyzed the metal flow characteristics,rib growth,metal streamline morphology,and equivalent strain evolution of TPHR under both unidirectional and reciprocating envelope forming processes.Physical tests were conducted to validate the effectiveness of the proposed reciprocating envelope forming process.The research results showed that,compared with unidirectional envelope forming,the reciprocating envelope forming process induced alternating clockwise and counterclockwise metal flow,reducing the tendency for unidirectional circumferential flow and resulting in more coordinated metal distribution and improved rib height uniformity.Additionally,reciprocating envelope forming produced continuous metal streamlines along the contour of TPHR,without any twisting of the streamlines.Furthermore,the equivalent strain on the high-rib surfaces formed by the reciprocating envelope die was greater than that on the non-rib surfaces constrained by the lower die,and the strain distribution was more uniform compared with unidirectional envelope forming.Physical tests successfully produced thin-walled components with high ribs exhibiting uniform rib height distribution,and the geometric shapes of the experimental sample closely matched those of the simulated sample.The reciprocating envelope forming process can produce TPHR of reasonable metal distribution,continuous metal streamlines,and uniform rib height and plastic deformation distribution.

关 键 词：高筋薄板件 往复包络成形 局部加载成形 工艺设计 塑性成形 

分 类 号：TG33[金属学及工艺—金属压力加工]