6061铝合金板材电磁冲孔-翻边复合成形工艺试验研究  

Experimental Investigations on Electromagnetic Punching-flanging Integrated Forming Process with 6061 Aluminum Alloy Sheets

作　　者：吴顶峰 汤康杰 陈楠[1] 童弈博 黄运凯 张旭[1] 崔俊佳[2] WU Dingfeng;TANG Kangjie;CHEN Nan;TONG Yibo;HUANG Yunkai;ZHANG Xu;CUI Junjia(College of Mechanical and Vehicle Engineering,Changsha University of Science and Technology,Changsha 410114,China;State Key Laboratory of Advanced Design and Manufacturing for Vehicle,Hunan University,Changsha 410082,China)

机构地区：[1]长沙理工大学机械与运载工程学院,长沙410114 [2]湖南大学整车先进设计制造技术全国重点实验室,长沙410082

出　　处：《精密成形工程》2025年第4期113-121,共9页Journal of Netshape Forming Engineering

基　　金：国家自然科学基金(52005055)。

摘　　要：目的针对铝合金板材采用传统翻边工艺时常出现翻边区域顶部和根部破裂的问题,提出一种新方法——电磁冲孔-翻边复合成形工艺试验(Electromagnetic Punching-Flanging,EMPF),即将电磁冲孔和电磁翻边两道工艺结合来制备具有良好性能的铝合金翻边件,并探究放电能量对冲孔-翻边各阶段成形效果的影响。方法以6061铝合金板材翻边结构为研究对象,进行了电磁冲孔-翻边复合成形工艺试验,对板材翻边高度、厚度分布、贴模性以及刃口形貌进行分析。结果在板材电磁冲孔阶段,落料以层裂、韧性孔口扩展型断裂、碎性型断裂与拉伸断裂复合形式被冲裁,放电能量对刃口宽度、层裂带宽度的影响较小;翻边区域顶部减薄率最大,从顶部到圆角位置,减薄率逐渐减小且减小速率逐渐减缓;当放电能量为9 kJ时,板材平均减薄率最小,其顶部和圆角位置的减薄率分别为18.375%和9.584%,并且成形板材与模具间隙(0.2 mm)最小,贴模性最好。结论合理控制放电能量有助于制造高质量电磁冲孔-翻边复合成形工件。The work aims to propose an Electromagnetic Punching-Flanging(EMPF)integrated forming process experiment,which combines electromagnetic punching and electromagnetic flanging to manufacture aluminum alloy flanging parts with excellent performance and explore the impact of discharge energy on the forming efficiency at each stage of punching and flanging,so as to solve the problem of cracking at the top and root of the traditional flanging process.The flanging structure of 6061 aluminum alloy sheets was studied by electromagnetic punching and flanging.The flanging height,thickness distribution,die fit and cutting edge morphology were analyzed.In the electromagnetic punching stage,results showed that the blanks were punched in the combining form of spalling,ductile orifice extension fracture,brittle fracture and tensile fracture.The discharge energy had little effect on the width of the cutting edge and spalling zone.The thinning rate at the top of the flanging area was the largest,and the thinning rate gradually decreased and the reduction rate gradually slowed down from the top to the fillet position.The average thinning rate of flanged sheets was the smallest under the discharge energy of 9 kJ.The thinning rate at the top and fillet position was 18.375%and 9.584%respectively.The gap between the formed sheets and the die was the smallest(0.2 mm),and the die fit was the best.In conclusion,reasonable control of discharge energy is helpful to manufacture high-quality electromagnetic punching-flanging integrated forming workpieces.

关 键 词：电磁冲孔-翻边 6061铝合金 试验研究 放电能量 微观组织 

分 类 号：TG156[金属学及工艺—热处理]