目的 针对难变形材料在大变形程度下传统挤压技术面临的成形力高、效率低等技术瓶颈,旨在开发一种超声振动辅助挤压复合成形新工艺,以实现低载荷、高质量的精密成形。方法 基于超声声软化效应的机理,并考虑超声波在金属介质中的能量衰减,构建了适用于6061铝合金的修正塑性本构模型。将该模型植入ABAQUS有限元平台,对超声辅助挤压管材过程进行数值模拟,并通过物理挤压实验对模拟结果进行验证。结果 超声振动辅助可显著降低材料的宏观变形抗力,峰值挤压力降幅达26.9%（从93 kN降至68 kN）。在微观与局部尺度上,超声振动优化了变形区的应力分布,有效抑制了应力集中,并促进了材料的塑性流动,表现为最大等效应变从0.576 5增加到0.656 7。管材整体应力分布所呈现的梯度变化,亦验证了超声能量在金属内部传播过程中的衰减特性。结论 本研究建立的修正本构模型能够准确描述超声辅助下6061铝合金在挤压变形过程中应力分布的优化行为,改善材料的塑性流变行为,并且能够精确预测上述物理现象,证明了该模型适用于超声辅助挤压过程的数值分析,为该技术的实际应用与优化提供可靠的理论依据和仿真预测工具。
Abstract
The work aims to propose a novel ultrasonic vibration-assisted extrusion process designed for low-load, high-quality precision forming to deal with the problem that conventional extrusion of difficult-to-deform materials suffers from high forming forces and low efficiency, especially under large deformations. A modified constitutive model for 6061 aluminum alloy was developed, incorporating the ultrasonic acoustic softening mechanism and accounting for energy attenuation in the metal medium. The model was implemented in ABAQUS to simulate the ultrasonic-assisted tube extrusion, with results subsequently validated by experiments. The findings demonstrated a significant reduction in macroscopic deformation resistance due to ultrasonic vibration. The peak extrusion force was reduced by 26.9%, from 93 kN to 68 kN. On a micro-scale, the ultrasonic vibration optimized the stress distribution within the deformation zone, mitigated stress concentrations, and enhanced material plastic flow, as indicated by the increase in maximum equivalent strain from 0.576 5 to 0.656 7. Furthermore, the observed stress gradient in the extruded pipe corroborated the phenomenon of ultrasonic energy attenuation. The developed modified constitutive model can accurately describe the optimized stress distribution behavior of 6061 aluminum alloy during ultrasound-assisted extrusion deformation, improve the plastic rheological behavior of the material, and precisely predict the above physical phenomena. It proves that this model is applicable to numerical analysis of ultrasonic-assisted extrusion, providing both a robust theoretical foundation and a predictive framework for the future application and optimization of this technology.
关键词
超声挤压 /
6061铝合金 /
声软化效应 /
超声衰减 /
本构模型 /
有限元仿真
Key words
ultrasonic extrusion /
6061 aluminium alloy /
acoustic softening effect /
ultrasonic attenuation /
isomorphic model /
finite element simulation
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基金
陕西省创新人才推进计划-科技创新团队（2021TD-27）; 国家自然科学基金（51705416）
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