目的 针对当前辊压-冲压工艺在金属箔材加工中存在的拔模角度大、冲压整形易断裂等痛点,创新设计了一种高深宽比箔材沟槽阵列特征辊压-冲压复合成形工艺。方法 设计采用不同尺寸的主辅辊压模具,同时仅对金属箔材一个沟槽特征进行成形,辊压时金属箔材进料端处于自由补料阶段,从而使材料减薄率减小。在冲压阶段,利用辊压半成品回弹力实现自定位,有效提升定位精度,提升材料利用率。结果 对0.1 mm金属箔材进行成形试验,其设计特征如下：沟槽深度为2.2 mm,槽脊与槽谷分别为3.1 mm、2.9 mm,沟槽特征32组。最终成品检验结果表明：长度、高度方向尺寸无偏差,最大减薄率仅为0.15%。结论 增大辊压模具两者尺寸差能降低重合度以及金属箔材的辊压延伸率;在静态与动态双重视角下,利用机械辅助设计软件对主辅辊轮外部轮廓进行防干涉设计,能实现辊压模具轮廓精准设计;针对冲压模具,可采用自定位固定方式,实现精准定位。此新型辊压-冲压成形工艺为批量金属箔材产业化应用提供了有益参考。
Abstract
The work aims to innovatively design a novel roll-pressing composite forming process for high-aspect-ratio foil groove array features to address the pain points of the current roll-pressing process in metal foil processing, such as large draft angles and easy fracture during stamping and shaping. For the method, main and auxiliary roll-pressing dies with different dimensions were adopted, which only formed one groove feature of the metal foil simultaneously. During roll-pressing, the feed end of the metal foil was in a free material supplement stage, thereby achieving a low material thinning rate. In the stamping stage, the elastic resilience of the roll-pressed semi-finished product was used to realize self-positioning, which effectively improved positioning accuracy and enhanced material utilization. Forming tests were conducted on a 0.1 mm-thick metal foil, with the designed features being a groove depth of 2.2 mm, a ridge width of 3.1 mm, a valley width of 2.9 mm, and a total of 32 grooves. Inspection of the final finished product showed no dimensional deviation in the length and height directions, and the maximum material thinning rate was only 0.15%. Conclusions indicate that increasing the dimensional difference between the two roll-pressing dies can reduce the coincidence degree and the roll-pressing elongation rate of the metal foil; carrying out anti-interference design on the outer contours of the main and auxiliary rollers using mechanical auxiliary design software from both static and dynamic perspectives enables precise contour design of the roll-pressing dies; and the stamping die can adopt a self-positioning fixing method to achieve accurate positioning. This new roll-pressing and stamping forming process provides a valuable reference for the industrial application of batch-produced metal foils.
关键词
金属箔材 /
高深宽比 /
凸起高度 /
重合度 /
沟槽
Key words
metal foil /
compound forming /
protrusion height /
coincidence degree /
groove
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基金
嘉兴市科技计划（2025CGZ027）; 浙江省高职教育“十四五”第二批教学改革项目（jg20240353）; 嘉兴职业技术学院重点科研项目（jzyz202506）
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