基于数值模拟的5A02铝合金管路端口旋转冲压扩口成形特征及工艺规范设计

苗新芳; 黄碧坤; 许增鑫; 刘承勃; 张松; 张昕

doi:10.3969/j.issn.1674-6457.2026.05.002

PDF(35058 KB)

精密成形工程 ›› 2026, Vol. 18 ›› Issue (5) : 12-23. DOI: 10.3969/j.issn.1674-6457.2026.05.002

轻合金成形

基于数值模拟的5A02铝合金管路端口旋转冲压扩口成形特征及工艺规范设计

苗新芳¹, 黄碧坤¹, 许增鑫¹, 刘承勃¹, 张松¹, 张昕^2,*

作者信息 +

Forming Characteristics and Process Specification Design of Rotary Stamping Expansion of 5A02 Aluminum Alloy Pipeline Ends Based on Numerical Simulation

MIAO Xinfang¹, HUANG Bikun¹, XU Zengxin¹, LIU Chengbo¹, ZHANG Song¹, ZHANG Xin^2,*

Author information +

文章历史 +

摘要

目的针对高速列车中以5A02铝合金接头及管路替代原有不锈钢管路的迫切需求,开发5A02铝合金管路旋转冲压扩口成形方法,获得成形工艺窗口。方法针对拟应用的6种管路规格,利用有限元数值模拟对管端旋转冲压扩口成形过程及特征进行了系统研究,分析了进给速度和凸模旋转速度等主要工艺参数对扩口成形过程的影响,提炼出铝合金旋转冲压扩口的成形特征及工艺规范。结果 5种规格（ϕ15 mm×1 mm、ϕ15 mm×1.5 mm、ϕ18 mm×1 mm、ϕ18 mm×1.5 mm、ϕ28 mm×1 mm）的铝合金管坯在旋转冲压扩口条件下成形性良好,可获得尺寸精度和表面质量较好的扩口件;而ϕ28 mm×2 mm规格的铝合金管坯在旋转冲压扩口过程中外缘应变过大,边缘成形质量明显下降,因此不适宜采用旋转冲压扩口工艺。从等效应力分布看,旋转冲压扩口过程中局部区域存在应力集中,可能产生微小的铝合金碎屑,影响内表面的成形质量。基于数值模拟结果,优化了旋转冲压扩口工艺参数,并通过实验验证了数值模拟的准确性。结论最终获得的优化工艺窗口为：进给速度2~6 mm/s,凸模旋转速度200~400 r/min。

Abstract

In order to address the urgent need to replace existing stainless steel pipelines in high-speed trains with assemblies and pipelines made of 5A02 aluminum alloy, the work aims to develop a rotary stamping expansion forming method for 5A02 aluminum alloy pipelines, and establish the corresponding forming process window. A numerical simulation study was carried out to investigate the rotary stamping expansion forming process and characteristics of pipeline ends of six specifications. The effects of feed speed and punch rotation speed on the expansion process were analyzed to identify the forming characteristics and develop process specifications for rotary stamping expansion of aluminum alloys. Five specifications (ϕ15 mm×1 mm, ϕ15 mm×1.5 mm, ϕ18 mm×1 mm, ϕ18 mm×1.5 mm, ϕ28 mm×1 mm) of aluminum alloy pipes exhibited good formability in the rotary stamping expansion process, yielding expanded parts with accurate sizes and good surface quality. In contrast, the ϕ28 mm×2 mm pipe experienced excessive strain at the outer edge during expansion, resulting in poor edge quality and rendering this specification unsuitable for the rotary expansion method. The equivalent stress distribution indicated that localized stress concentrations occurred during the expansion process, which could lead to the formation of aluminum debris and consequently affected the inner surface quality. Based on the simulation results, the expansion process parameters were optimized and then the accuracy of the numerical simulation was validated by experiments. The optimized process window is determined as a feed speed of 2-6 mm/s and a punch rotation speed of 200-400 r/min.

导出引用

苗新芳, 黄碧坤, 许增鑫, 刘承勃, 张松, 张昕. 基于数值模拟的5A02铝合金管路端口旋转冲压扩口成形特征及工艺规范设计[J]. 精密成形工程. 2026, 18(5): 12-23 https://doi.org/10.3969/j.issn.1674-6457.2026.05.002

MIAO Xinfang, HUANG Bikun, XU Zengxin, LIU Chengbo, ZHANG Song, ZHANG Xin. Forming Characteristics and Process Specification Design of Rotary Stamping Expansion of 5A02 Aluminum Alloy Pipeline Ends Based on Numerical Simulation[J]. Journal of Netshape Forming Engineering. 2026, 18(5): 12-23 https://doi.org/10.3969/j.issn.1674-6457.2026.05.002

中图分类号： TG316.3

参考文献

[1] 丁叁叁, 陈大伟, 刘加利. 中国高速列车研发与展望[J]. 力学学报, 2021, 53(1): 35-50.
DING S S, CHEN D W, LIU J L.Research, Development and Prospect of China high-Speed Train[J]. Chinese Journal of Theoretical and Applied Mechanics, 2021, 53(1): 35-50.
[2] 王巧玲, 詹梅, 李宏伟, 等. 大直径薄壁管双扩口成形机理与工艺研究[J]. 塑性工程学报, 2019, 26(3): 104-112.
WANG Q L, ZHAN M, LI H W, et al.Research on Forming Mechanism and Process of Double Flaring Tubes with Large Diameter and Thin Wall[J]. Journal of Plasticity Engineering, 2019, 26(3): 104-112.
[3] 寸文渊, 钱文清, 舒阳, 等. 航空导管扩口成形快速模拟研究[J]. 塑性工程学报, 2021, 28(3): 58-66.
CUN W Y, QIAN W Q, SHU Y, et al.Research on Fast Simulation of Aviation Tube Flaring Forming[J]. Journal of Plasticity Engineering, 2021, 28(3): 58-66.
[4] 鲍益东, 钱文清, 陈晓豫, 等. 航空扩口导管轴向收缩量快速预测方法[J]. 机械工程学报, 2020, 56(10): 102-109.
BAO Y D, QIAN W Q, CHEN X Y, et al.Fast Prediction Method of the Axial Contraction of Aviation Flared Tube[J]. Journal of Mechanical Engineering, 2020, 56(10): 102-109.
[5] ROY M J, MAIJER D M.Analysis and Modelling of a Rotary Forming Process for Cast Aluminium Alloy A356[J]. Journal of Materials Processing Technology, 2015, 226: 188-204.
[6] KHALIL H A R, ABDEL-MAGIED R K, ELSHEIKH M N. An Experimental Analysis of a Flaring Process for Tube Ends Using a Novel Spinning Tool[J]. The International Journal of Advanced Manufacturing Technology, 2017, 92(1): 157-165.
[7] SEN D, KATIYAR B S, PANDA S K, et al.Numerical Simulation on End Expansion of Tubes Fabricated through Friction Stir Welding and Validation of Fracture Behaviour[J]. CIRP Journal of Manufacturing Science and Technology, 2023, 43: 227-241.
[8] YAN J L, YAO S G, XU P, et al.Theoretical Prediction and Numerical Studies of Expanding Circular Tubes as Energy Absorbers[J]. International Journal of Mechanical Sciences, 2016, 105: 206-214.
[9] CHEN C, ZHAO Y J, WANG D Y, et al.Study on Joining for Thin-Walled Aluminum Alloy/Steel Tubes by Electromagnetic Flanging Process[J]. Metals, 2023, 13(9): 1529.
[10] 彭江涛, 李宏伟, 詹梅, 等. 5A02铝合金管端旋转冲压双扩口成形过程精确预测[J]. 锻压技术, 2021, 46(9): 112-117.
PENG J T, LI H W, ZHAN M, et al.Precise Prediction of Double Flaring Forming Process of 5A02 Aluminum Alloy Tube End by Rotating-Stamping[J]. Forging & Stamping Technology, 2021, 46(9): 112-117.
[11] 唐臣升, 孙朝海, 孙进, 等. 铝合金导管扩口柔性夹持工装技术[J]. 工具技术, 2023, 57(10): 118-122.
TANG C S, SUN C H, SUN J, et al.Process Equipment for Flexibly Hoding in Flaring Aluminum-Alloy Pipe[J]. Tool Engineering, 2023, 57(10): 118-122.
[12] ZHAN M, GUO J, FU M W, et al.Formation Mechanism and Control of Flaring in Forward Tube Spinning[J]. The International Journal of Advanced Manufacturing Technology, 2018, 94(1): 59-72.
[13] 寸文渊, 张晶, 崔保金, 等. 基于CAE的导管精确扩口成形技术[J]. 锻压技术, 2020, 45(10): 73-79.
CUN W Y, ZHANG J, CUI B J, et al.Precise Flaring Forming Technology of Catheter Based on CAE[J]. Forging & Stamping Technology, 2020, 45(10): 73-79.
[14] QIAN W X, WU N X, LI H, et al.Simulation Analysis and Experimental Study of the Strength of Aluminum Alloy Suspension Structure[J]. Materials, 2022, 16(1): 128.
[15] LU Y H.Study of Tube Flaring Ratio and Strain Rate in the Tube Flaring Process[J]. Finite Elements in Analysis and Design, 2004, 40(3): 305-318.
[16] WU Y N, LIAO H C, TANG Y Y.Enhanced High-Cycle Fatigue Strength of Al-12Si-4Cu-1.2Mn-T6 Cast Aluminum Alloy at Room Temperature and 350 C[J]. Materials Science and Engineering: A, 2021, 825: 141917.
[17] LI J, GAO G J, DONG H P, et al.Study on the Energy Absorption of the Expanding-Splitting Circular Tube by Experimental Investigations and Numerical Simulations[J]. Thin-Walled Structures, 2016, 103: 105-114.
[18] ZHAO G Y, LU C J, ZHANG R Y, et al.Uneven Plastic Deformation Behavior of High-Strength Cast Aluminum Alloy Tube in Multi-Pass Hot Power Backward Spinning[J]. The International Journal of Advanced Manufacturing Technology, 2017, 88(1): 907-921.
[19] XIA Q X, XIAO G F, LONG H, et al.A Review of Process Advancement of Novel Metal Spinning[J]. International Journal of Machine Tools and Manufacture, 2014, 85: 100-121.
[20] WU R L, DAI W, LUO J K, et al.Aluminum Alloy Hot Stamping and Forming Technology: A Review[J]. Materials, 2025, 18(8): 1694.
[21] TRZEPIECIŃSKI T. Recent Developments and Trends in Sheet Metal Forming[J]. Metals, 2020, 10(6): 779.
[22] LOSSEN B, ANDREIEV A, STOLBCHENKO M, et al.Friction-Spinning—Grain Structure Modification and the Impact on Stress/Strain Behaviour[J]. Journal of Materials Processing Technology, 2018, 261: 242-250.
[23] ZHAN M, YANG H, GUO J, et al.Review on Hot Spinning for Difficult-to-Deform Lightweight Metals[J]. Transactions of Nonferrous Metals Society of China, 2015, 25(6): 1732-1743.
[24] XIA Q X, ZHU N Y, CHENG X Q, et al.The Classification and a Review of Hot Power Spinning of Difficult-to-Deform Metals[J]. International Journal of Materials and Product Technology, 2017, 54(1/2/3): 212.