目的 利用有限元数值模拟和响应面法研究AZ31B/Q345薄板辅热无铆连接成形机理、模具改进和工艺优化;通过实验研究AZ31B和不同强度碳钢薄板无铆连接工艺的可行性。方法 以AZ31B/Q345薄板为研究对象,建立二维轴对称有限元模型,对比分析模具改进前和改进后无铆连接成形过程中的接头形貌演化规律;以颈部厚度和互锁量为评价指标,以凸模半径、凹模深度和凹模半径等参数为变量,采用响应面法对改进的模具进行工艺优化;通过AZ31B/Q235、AZ31B/Q345和AZ31B/Q460薄板辅热无铆连接实验分析不同钢板对接头连接质量的影响规律。结果 在未改进模具条件下,上层AZ31B薄板易发生回流起翘,难以形成有效互锁;在改进模具条件下,接头可以形成有效互锁。凹模半径对颈部厚度影响较为敏感,凹模深度对互锁量影响较为敏感,优化后凸模半径2.8 mm、凹模深度1.5 mm和凹模半径3.9 mm较为合理。结论 改进模具可实现AZ31B/Q235、AZ31B/Q345薄板有效无铆连接;由于Q460薄板强度过大,本文选取预成形无铆连接工艺获得有效连接接头。
Abstract
The work aims to employ the finite element simulation and response surface methodology to investigate the forming mechanism, tool improvement, and process optimization of heat-assisted clinching for AZ31B/Q345 sheets, and conduct experiments to evaluate the feasibility of clinching AZ31B magnesium alloy with carbon steel sheets of different strength levels. Taking AZ31B/Q345 sheets as the research objects, a two-dimensional axisymmetric finite element model was established to compare and analyze the evolution of joint morphology during the clinching process before and after tool improvement. Neck thickness and interlock value were selected as evaluation indexes, and the punch radius, die depth, and die radius were taken as variables to optimize the improved tool by response surface methodology. In addition, heat-assisted clinching experiments were carried out on AZ31B/Q235, AZ31B/Q345, and AZ31B/Q460 sheets to analyze the influence of different steel sheets on joint quality. Under the conventional tool condition, the upper AZ31B sheet was prone to reverse flow and warping, making it difficult to form an effective interlock, whereas under the improved tool condition, an effective interlock could be achieved. The die radius was more sensitive to neck thickness, while the die depth was more sensitive to interlock value. After optimization, a punch radius of 2.8 mm, a die depth of 1.5 mm, and a die radius of 3.9 mm were found to be reasonable. The improved tool can achieve effective clinching of AZ31B/Q235 and AZ31B/Q345 sheets. Since the strength of the Q460 sheet is excessively high, a preforming clinching process is adopted in this study to obtain effective joints.
关键词
AZ31B镁合金 /
碳钢薄板 /
无铆连接 /
改进模具 /
响应面优化 /
预成形无铆连接
Key words
AZ31B magnesium alloy /
carbon steel sheet /
clinching /
improved tool /
response surface optimization /
preforming clinching
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基金
中央引导地方科技发展资金（226Z1809G）
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