目的 以2024-O铝合金跑道孔为研究对象,探究线圈层数、放电电压及放电电容等参数对跑道孔翻边贴膜性与减薄率的影响。方法 基于电磁翻边过程的有限元数值模拟与分析,对翻边过程中涉及的各项工艺参数对翻边结果的影响进行数值模拟,并通过贴模间隙、减薄率2个指标对最终翻边质量进行评估,在减薄率不超过20%的情况下,以贴模间隙最小作为综合成形质量最佳的判断标准。结果 当线圈串联层数超过2时,因为第3层线圈距离板料过远,所以它对板料的影响远小于第2层的影响。过高的放电电压会导致板料运动速度过高,与模具发生碰撞,导致成形效果差,过低的放电电压会使板料无法获得足够的运动速度。电容量越低,放电频率越高,板料在变形初期获得的运动速度越大。结论 成形质量的影响因素包括线圈串联层数、放电电压、放电电容等。对于跑道孔,2层线圈串联为最佳线圈设计方式,搭配11 kV的放电电压并选择106.5 μF放电电容可获得最佳成形效果,此时,贴模间隙指标达到工艺要求,两圆边顶点间距的实测值与模拟值相差0.02 mm。
Abstract
The work aims to investigate the electromagnetic flanging process of 2024-O aluminum alloy obround holes, focusing on the effects of coil series layers, discharge voltage, and discharge capacitance on mold-fitting performance and thinning rate. Through finite element numerical simulation and analysis of the electromagnetic flanging process, the effect of various process parameters on flanging results was systematically examined. The forming quality was evaluated using two indicators: mold-fitting gap and thinning rate, with the optimal forming criteria defined as achieving minimal mold-fitting gap while maintaining thinning rate below 20%. The results demonstrated that when employing more than two series-connected coil layers, the third layer exhibited significantly reduced effect on sheet metal deformation due to excessive distance from the workpiece. Excessive discharge voltage induced overspeed deformation leading to mold collision and poor forming quality, while insufficient voltage failed to provide adequate deformation velocity. Lower capacitance values corresponded to higher discharge frequencies, resulting in greater initial deformation velocities. The critical parameters affecting forming quality include the number of series-connected coil layers, discharge voltage, and discharge capacitance. For obround hole flanging, the optimal configuration combines two series-connected coil layers with 11 kV discharge voltage and 106.5 μF capacitance. This parameter combination achieves mold-fitting gaps meeting process requirements, with a mere 0.02 mm discrepancy between simulated and measured values for the apex spacing between circular edges.
关键词
2024铝合金 /
电磁翻边 /
成形精度 /
有限元 /
工艺优化
Key words
2024 aluminum alloy /
electromagnetic flanging /
forming accuracy /
finite element /
process optimization
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基金
国家自然科学基金企业创新发展联合基金（U24B2054）
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