孙宏博,杨晨.6A02铝合金异形截面小弯曲半径薄壁管液压成形工艺研究[J].精密成形工程,2023,15(5):1-9.
SUN Hong-bo,YANG Chen.Hydroforming Process of 6A02 Aluminum Alloy Thin-walled Tube withSpecial Section and Small Bending Radius[J].Journal of Netshape Forming Engineering,2023,15(5):1-9. |
| 6A02铝合金异形截面小弯曲半径薄壁管液压成形工艺研究 |
| Hydroforming Process of 6A02 Aluminum Alloy Thin-walled Tube withSpecial Section and Small Bending Radius |
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| DOI：10.3969/j.issn.1674-6457.2023.05.001 |
| 中文关键词: 液压成形 薄壁管 小弯曲半径 6A02铝合金 加载路径 |
| 英文关键词: hydroforming thin-walled tube small bending radius 6A02 aluminum alloy loading path |
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| 中文摘要: |
| 目的 研究6A02铝合金异形截面薄壁管的液压成形过程，改进管件的成形质量。方法 使用Abaqus软件进行数值模拟，通过考察管件壁厚分布情况、管件轴线的最小弯曲半径及管壁与模具贴合情况，研究了内压、轴向进给量、加载路径及合模过程中的内压与进给对成形质量的影响，并提出了合模力–轴向进给–内压三者同时配合的加工方法。结果 通过数值模拟确定了无轴向进给情况下管件薄弱处发生破裂时的内压为7.5 MPa，发生起皱前的最大轴向进给量为2 mm，最低整形内压为80 MPa。确定了在合模过程中进给0.75 mm、合模后继续按照特定加载路径进行内压提升和轴向进给、最后施加80 MPa的整形压力的情况下成形效果最好。通过此路径加工出的管件最小壁厚为0.42 mm，最大减薄率为16%，轴线最小弯曲半径为1.258 mm，与模具间隙面积为0.065 mm2。结论 适当的内压–轴向进给可以实现较好的成形质量。在合模过程中，施加与合模力相配合的轴向进给和内压能增加管件弯曲处薄弱部分的补料量，改善管件在合模后的壁厚分布情况，进一步提升管件最终成形质量。 |
| 英文摘要: |
| The work aims to study the hydroforming process of 6A02 aluminum alloy thin-walled tube with special section and improve the forming quality of tube. Abaqus was used for numerical simulation and the effects of internal pressure, axial feed rate, loading path form and internal pressure and feed in the process of die closing on the forming quality were studied by investigating the parameters such as the distribution of tube wall thickness, the minimum bending radius at the tube axis and the fitting condition between tube and die. Then, a processing method of simultaneously considering die closing force, axial feed and internal pressure was proposed. Through numerical simulation, it was determined that the internal pressure when the weak part of the tube broke without axial feed was 7.5 MPa, the maximum axial feed before wrinkling was 2 mm, and the minimum internal pressure for forming was 80 MPa. The best forming effect could be achieved when the feed was 0.75 mm during the die closing process, the internal pressure lifting and axial feed were continued according to the specific loading path after the die closing and the forming pressure of 80 MPa was finally applied. After processed by this loading path, the minimum tube thickness was 0.42 mm, the maximum thinning rate was 16%, the minimum bending radius of the axis was 1.258 mm, and the clearance area with the die is 0.065 mm2. Proper internal pressure-axial feed can achieve better forming quality. During the die closing process, applying the axial feed and internal pressure corresponding to the die closing force can increase the feeding amount of the weak part at the bend of the tube, improve the wall thickness distribution of the tube after die closing, and further enhance the final forming quality of the tube. |
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