目的 通过成形极限图对多道次成形过程中材料的应变进行监控,以确定成形道次及各道次拉延比,实现大高径比的金属箔材微杯形拉深件的经济有效制备。方法 首先,基于数字图像相关技术和Holmberg单轴拉伸测试,确定50 μm厚度退火态TA1纯钛箔的成形极限。其次,基于成形极限和数值模拟,设计直径0.6 mm、高度1.12 mm的目标微杯形拉深件的成形工艺及模具。最后,通过多道次微拉深试验,分析各道次材料的变形行为和可成形性,以验证成形工艺的可行性。结果 通过分别对冲头直径为1、0.8、0.6 mm的三道次微拉深成形工艺方案进行模拟分析,发现随着拉深道次的增加,微杯各部位应变在成形极限图中的位置逐渐从安全区向破裂区靠近,并在第三道次时达到材料成形极限,无失效风险。尽管微杯杯底圆角处和侧壁接近杯口处存在减薄现象,但最终成形的微杯在这2个位置的减薄量分别为18%和21%,厚度分布较为均匀。结论 经过拉延比分别为1.6、1.25和1.33的多道次微拉深成形,成功制备出无表面缺陷、厚度分布较为均匀的目标微杯。成形极限辅助和数值模拟相结合的方法能够有效指导工艺及模具设计。
Abstract
To economically and effectively produce metal foil micro cup parts with a large height-to-diameter ratio, the work aims to monitor the strain state during multi-stage forming with the forming limit diagram and determine the number of forming stages and the drawing ratio for each stage. Firstly, the forming limit of 50 μm thick annealed TA1 pure titanium foils was determined through the digital image correlation and the Holmberg uniaxial tensile test. Then, the forming process and die for a target micro cup-shaped deep-drawn part (0.6 mm in diameter and 1.12 mm in height) were designed based on the forming limit diagram and numerical simulation. Finally, multi-stage micro deep drawing tests were conducted. The deformation behavior and formability of the material at each stage were analyzed to assess the feasibility of the forming process. Through simulations of micro-deep-drawing processes with punch diameters of 1 mm, 0.8 mm, and 0.6 mm, it was found that as the number of drawing stages increased, the strain at each position of the micro-cup gradually approaches the fracture zone from the safe zone in the forming limit diagram. By the third stage, the material reached its forming limit without the risk of failure. Although thinning occurred at the base fillet of the micro cup and near the rim of the sidewall, the final formed micro cup exhibited thinning of 18% and 21% at these two positions, respectively, while maintaining a relatively uniform thickness distribution. Through multi-stage micro deep drawing with drawing ratios of 1.6, 1.25, and 1.33, target micro cups are successfully produced, exhibiting no surface defects and a relatively uniform thickness distribution. Studies indicate that integrating forming limits with numerical simulations can effectively guide processes and die design.
关键词
TA1纯钛箔 /
多道次微拉深 /
成形极限 /
数值模拟 /
工艺和模具设计
Key words
TA1 pure Ti foils /
multi-stage micro deep drawing /
forming limit /
numerical simulation /
process and die design
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基金
国家自然科学基金（52275358）;太原科技大学科研启动资金项目（20232106,20242076）;山西省高等学校科技创新计划项目（2024L247）
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