轨道交通用工业AA5083铝合金快速超塑性成形技术研究
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摘要
采用快速超塑成形技术对高铁车辆侧壁外板进行成形试验,结果表明,其生产效率高、成本低,能够成功解决传统冲压工艺无法实现复杂空间曲面铝合金零件以及传统超塑成形工艺成形周期长、效率低的难题。通过系列试验研究,确定了热冲压工艺与超塑成形工艺相结合的快速超塑成形技术,成功使用厚度为4 mm的工业用铝合金薄板制造了圆角极小(R≤4 mm)的高铁边缘蒙皮和直壁拉深成形的大型地铁门框零件(h≈80 mm),该成形件具有尺寸精度高、壁厚分布均匀、形状稳定性高等优点,同时其力学性能满足使用要求。
The forming tests of side wall outer panel of metro vehicle were carried out by quick superplastic forming. The results show that the production efficiency is high,the cost is low and it can successfully solve the problems that the traditional stamping process can not achieve complex surface aluminum parts and the traditional superplastic forming process has long forming cycle and low efficiency. The quick superplastic forming technology combined hot drawing and superplastic forming was determined though a series of experiments. The high-speed rail edge skin with a very small fillet shape( R≤4 mm) and the large-size subway door frame part( h≈80 mm) formed by straight wall deep drawing were manufactured by using industrial aluminum alloy sheet with thickness of 4 mm. The formed parts show the advantages of high dimensional accuracy,uniform wall thickness distribution and high shape stability. Meanwhile,the mechanical properties of formed parts can meet the operating requirements.
The forming tests of side wall outer panel of metro vehicle were carried out by quick superplastic forming. The results show that the production efficiency is high,the cost is low and it can successfully solve the problems that the traditional stamping process can not achieve complex surface aluminum parts and the traditional superplastic forming process has long forming cycle and low efficiency. The quick superplastic forming technology combined hot drawing and superplastic forming was determined though a series of experiments. The high-speed rail edge skin with a very small fillet shape( R≤4 mm) and the large-size subway door frame part( h≈80 mm) formed by straight wall deep drawing were manufactured by using industrial aluminum alloy sheet with thickness of 4 mm. The formed parts show the advantages of high dimensional accuracy,uniform wall thickness distribution and high shape stability. Meanwhile,the mechanical properties of formed parts can meet the operating requirements.
引文
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[10]吴晓炜,王勇,梁海建,等.铝合金覆盖件快速超塑性成形技术[J].塑性工程学报,2012,19(1):1-5.WU Xiaowei,WANG Yong,LIANG Haijian,et al. Rapid superplastic forming technology for aluminum alloy cover parts[J].Journal of Plasticity Engineering,2012,19(1):1-5.
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[12]刘勤.金属的超塑性[M].上海:上海交通大学出版社,1989.LIU Qin. Metal superplasticity[M]. Shanghai:Shanghai Jiao Tong University Press,1989.
[13]徐清波,陶友瑞,米芳. 5083铝合金高温流变本构关系研究[J].矿冶工程,2013,33(5):124-126.XU Qingbo, TAO Yourui, MI Fang. Constitutive equation of rheological properties for 5083 aluminum alloy at elevated temperature[J]. Mining and Metallurgical Engineering, 2013, 33(5):124-126.
[2] DUNWOODY B J. The production of automotive body panels in5083 SPF aluminium alloy[J]. Materials Science Forum,2001,357-359:59-64.
[3] BARNES A J. Industrial applications of super-plastic forming:trends and prospects[J]. British Phycological Journal,2001,357(3):3-16.
[4] WANG G F,SUN C,LIU S F,et al. Research on quicksuperplastic forming technology of aluminum alloy complexcomponents[J]. Materialwissenschaft und Werkstofftechnik, 2015, 45:854-859.
[5]何泽洲,鲁世红,王亦金,等.国产5083铝合金复杂零件超塑性成形工艺研究[J].热加工工艺,2018,47(17):112-116.HE Zezhou,LU Shiqiang,WANG Yijin,et al. Study on superplastic forming process of domestic 5083 aluminum alloy complex parts[J]. Hot Working Technology,2018,47(17):112-116.
[6]齐飞,张臣,周永松,等.退火工艺制度对5083铝合金板材超塑性的影响[J].塑性工程学报,2018,25(2):196-201.QI Fei,ZHANG Chen,ZHOU Yongsong,et al. Effect of an nealing process on superplasticity of 5083 aluminum alloy sheet[J].Journal of Plasticity Engineering,2018,25(2):196-201.
[7]李志强,陆文林,王伟亮,等. 5A06薄壁壳体超塑胀形过程壁厚分布规律及其控制[J].塑性工程学报,2017,24(1):108-113.LI Zhiqiang, LU Wenlin, WANG Weiliang, et al. The wall thickness distribution and control of 5A06 thin-walled shell during superplastic bulging process[J]. Journal of Plasticity Engineering,2017,24(1):108-113.
[8]顾义斌.轨道交通用国产供货态5083铝合金超塑性研究[C]//第十五届全国塑性工程学会年会暨第七届全球华人塑性加工技术交流会学术会议论文集,济南:2017.GU Yibin. Research on superplasticity of domestically available5083 aluminum alloy for rail transit[C]//Proceedings of the15th National Plastics Engineering Society Annual Meeting and the7th Global Chinese Plastic Processing Technology Exchange Conference,Jinan:2017.
[9]蔡云,陈夫进.正反胀形对铝合金超塑成形件厚度的影响[J].铸造技术,2015,36(2):514-516.CAI Yun,CHEN Fujin. Influence of positive and negative dilatation on thickness of aluminum alloy superplastic formed parts[J].Foundry Technology,2015,36(2):514-516.
[10]吴晓炜,王勇,梁海建,等.铝合金覆盖件快速超塑性成形技术[J].塑性工程学报,2012,19(1):1-5.WU Xiaowei,WANG Yong,LIANG Haijian,et al. Rapid superplastic forming technology for aluminum alloy cover parts[J].Journal of Plasticity Engineering,2012,19(1):1-5.
[11] KAIBYSHEV R,MUSIN F,LESUER D R,et al. Superplastic behavior of an Al-Mg alloy at elevated temperatures[J]. Materials Science&Engineering A,2003,342:169-177.
[12]刘勤.金属的超塑性[M].上海:上海交通大学出版社,1989.LIU Qin. Metal superplasticity[M]. Shanghai:Shanghai Jiao Tong University Press,1989.
[13]徐清波,陶友瑞,米芳. 5083铝合金高温流变本构关系研究[J].矿冶工程,2013,33(5):124-126.XU Qingbo, TAO Yourui, MI Fang. Constitutive equation of rheological properties for 5083 aluminum alloy at elevated temperature[J]. Mining and Metallurgical Engineering, 2013, 33(5):124-126.