目的 针对镁合金在实际生产中材料利用率低、无法在室温下进行冲压批量生产的问题,以飞行器镁合金口盖为研究对象,确定其热冲压成形最佳工艺参数。方法 基于Abaqus有限元仿真软件,建立了飞行器镁合金口盖热压成形有限元模型,分别探究了压边力、温度、侧壁斜度、凸缘圆角半径、底部圆角半径、摩擦系数对镁合金口盖热压成形的影响规律,基于有限元仿真结果对镁合金口盖三维模型进行尺寸优化。结果 镁合金口盖热压成形选用无压边的方案效果更佳;当温度为220 ℃时,壁厚减薄率最小;当镁合金口盖侧壁斜度为60°时,可使镁合金口盖凸缘区域保持较小的壁厚差;当凸缘圆角半径≤4 mm或底部圆角半径≤10 mm时,镁合金口盖热压成形后会发生失效;凸缘圆角处壁厚、底部圆角处壁厚及底部平面区域壁厚均随摩擦系数的变大而变小。结论 在凸缘圆角半径为8 mm、底部圆角半径为14 mm、侧壁斜度为60°、成形温度为220 ℃的条件下,能够成功获得满足使用要求的镁合金口盖零件。在该工艺参数下,可实现ZK61M镁合金口盖的快速大批量生产。
Abstract
The work aims to take aircraft magnesium alloy covers as the research object to determine the optimal hot stamping process parameters to solve the problem of low material utilization rate of magnesium alloy in actual production and unable to carry out stamping mass production at room temperature. Based on ABAQUS finite element simulation software, a finite element model for hot stamping of aircraft magnesium alloy covers was established. The influence laws of blank holder force, temperature, sidewall slope, flange fillet radius, bottom fillet radius and friction coefficient on hot stamping of magnesium alloy covers were explored respectively. Based on the finite element simulation results, a three-dimensional model of magnesium alloy covers was optimized. The results showed that the effect of the scheme without blank holders was better than that of the scheme without blank holders; When the temperature was 220 ℃, the wall thickness reduction rate of hot stamping of magnesium alloy covers was the minimum; When the sidewall slope of the magnesium alloy covers was set to 60°, the flange area of the magnesium alloy covers could maintain a small wall thickness difference; When the flange fillet radius ≤4 mm or the bottom fillet radius ≤10 mm, the magnesium alloy covers would crack after hot pressing; The wall thickness of the flange fillet, the bottom fillet and the bottom plane area all decreased with the increase of the friction coefficient. In conclusion, under the conditions of the flange fillet radius of 8 mm, the bottom fillet radius of 14 mm, the sidewall slope of 60°, and the forming temperature of 220 ℃, magnesium alloy cover parts that meet the use requirements can be successfully obtained. Under this process parameter, the rapid mass production of ZK61M magnesium alloy covers can be realized.
关键词
ZK61M /
镁合金口盖 /
热冲压成形 /
Abaqus /
有限元分析
Key words
ZK61M /
magnesium alloy covers /
hot stamping /
Abaqus /
finite element analysis
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基金
上海市优秀学术/技术带头人计划项目（21XD1433900）
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