变曲率抛物线型零件充液拉深工艺优化
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摘要
基于抛物线型零件充液拉深工艺,采用理论分析、有限元仿真及工艺试验优化了工艺参数,利用理论公式计算得到了关键参数的理论值,总结得到了该零件的理论成形工艺窗口,通过有限元进一步精确了工艺窗口的范围,得到了经仿真优化的液力加载曲线,结合工艺试验调整了局部参数,对试验中出现的成形缺陷进行了原因分析并给出了解决方案,经过验证得到了用于生产加工的实际液力加载轨迹,给出了抛物线型零件充液拉深一般的液力加载曲线特征,可作为同类型零件充液拉深成形工艺参考。
Based on the process of hydrodynamic deep drawing of variable curvature parabolic part,the process parameters are optimized through theoretical analysis,finite element numerical simulation and experimental test.The theoretical value of Key parameters are calculated by theoretical equation,and theoretical forming limit range of hydrodynamic deep drawing of the part is identified,rough process window is summarized,then future precise process window and optimal pressure curve obtained by finite element numerical simulation,the value of local points of pressure loading curve are adjusted by experiments,and the mechanism of forming defects occurred in experiments are analyzed and corresponding solutions are given at last,the actual pressure loading curve which can be used in production processing is obtained and optimized through experiment verification, the general characteristics of pressure loading curve in the process of hydrodynamic deep drawing of parabolic part is concluded in the conclusion,can be used as a reference for hydrodynamic deep drawing process of similar part.
Based on the process of hydrodynamic deep drawing of variable curvature parabolic part,the process parameters are optimized through theoretical analysis,finite element numerical simulation and experimental test.The theoretical value of Key parameters are calculated by theoretical equation,and theoretical forming limit range of hydrodynamic deep drawing of the part is identified,rough process window is summarized,then future precise process window and optimal pressure curve obtained by finite element numerical simulation,the value of local points of pressure loading curve are adjusted by experiments,and the mechanism of forming defects occurred in experiments are analyzed and corresponding solutions are given at last,the actual pressure loading curve which can be used in production processing is obtained and optimized through experiment verification, the general characteristics of pressure loading curve in the process of hydrodynamic deep drawing of parabolic part is concluded in the conclusion,can be used as a reference for hydrodynamic deep drawing process of similar part.
引文
[1]郎利辉,张士宏,康达昌.板液压成形及无模充液拉深技术[J].塑性工程学报,2002,9(4):26-30Lang L H,Zhang S H,Kang D C.About sheet hydroforming and hydromechanical deep drawing without draw die[J].Journal of Plasticity Engineering,2002,9(4):26-30.(in Chinese)
[2]李涛,郎利辉,周贤宾.先进板材液压成形技术及其进展[J].塑性工程学报,2006,13(3):30-34Li T,Lang L H,Zhou X B.Recent developments of the advanced sheet hydroforming[J].Journal of Plasticity Engineering,2006,13(3):30-34.(in Chinese)
[3]郎利辉.板材充液先进成形技术[M].北京:国防工业出版社,2014:3-4Lang L H.Innovative sheet hydroforming and warm/hot hydroforming[M].Beijing:National Defense Industry Press,2014:3-4(in Chinese)
[4]Bay N.Forming limits in hydromechanical deep drawing[J].Annals of the CIRP,1994,43(1):253-256
[5]Yang D Y,Kim J B,Wlee D.Investigation into manufacturing of very long cups by hydromechanical deep-drawing and ironing with controlled radial pressure[J].Annals of the CIRP,1995,44(1):255-258
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[7]徐永超,陈宇,苑士剑.半球底筒形件充液拉深加载路径优化研究[J].哈尔滨工业大学学报,2008,40(7):1076-1080Xu Y C,Chen Y,Yuan S J.Loading path optimization of hydro-mechanical deep drawing of the cup with a semi-ball bottom[J].Journal of Harbin Institute of Technology,2008,40(7):1076-1080(in Chinese)
[8]Lang L H,Wang Y M,Xie Y S,et al.Pre-bulging effect during sheet hydroforming process of aluminum alloy box with unequal height and flat bottom[J].Transactions of Nonferrous Metals Society of China,2012,22(2):302-307
[9]Gorji A,Alavi-hashemi H,Bakhshi-jooybari M,et al.Investigation of hydrodynamic deep drawing for conical cylindrical cups[J].International Journal Advanced Manufacturing Technology,2011,56:915-927
[10]刘晓晶,徐永超,苑士剑.反胀压力对铝合金球底筒形件充液拉深过程的影响[J].塑性工程学报,2008,15(3):42-46Liu X J,Xu Y C,Yuan S J.The influence of inverse bulging pressure on the hydrodynamic deep drawing process of aluminium alloy cylindrical cups with a hemispherical bottom[J].Journal of Plasticity Engineering,2008,15(3):42-46(in Chinese)
[11]Kawka M,Olejnik L,Rosochowski A,et al.Simulation of wrinkling in sheet metal forming[J].J Materials Processing Technology,2001,109:283-289
[12]Vollertsen F.Processes Layout Avoiding Reverse Drawing Wrinkles in Hydroforming of Sheet Metal[J].Ann Crip,2002,52(1):203-208
[13]陈一哲,刘伟,苑士剑.薄板液压成形起皱预测及控制研究进展[J].机械工程学报,2016,52(4):20-27Chen Y Z,Liu W,Yuan S J.Research development on wrinkling prediction and suppression for sheet hydroforming of thin-walled deep drawing parts[J].Journal of Mechanical Engineering,2016,52(4):20-27(in Chinese)
[14]Liu X,Xu Y C,Yuan S J.Hydro-forming of aluminum alloy complex-shaped components[J].Transactions of Nonferrous Metals Society of China,2011,21(2):417-422
[15]孟宝,万敏,吴向东,等.板材充液拉深动态加载系统开发与应用[J].机械工程学报,2013 49(24):60-66Meng B,Wan M,Wu X D,et al.Development of dynamic loading system for sheet metal hydrodynamic deep drawing and its application[J].Journal of Plasticity Engineering,2013 49(24):60-66(in Chinese)
[2]李涛,郎利辉,周贤宾.先进板材液压成形技术及其进展[J].塑性工程学报,2006,13(3):30-34Li T,Lang L H,Zhou X B.Recent developments of the advanced sheet hydroforming[J].Journal of Plasticity Engineering,2006,13(3):30-34.(in Chinese)
[3]郎利辉.板材充液先进成形技术[M].北京:国防工业出版社,2014:3-4Lang L H.Innovative sheet hydroforming and warm/hot hydroforming[M].Beijing:National Defense Industry Press,2014:3-4(in Chinese)
[4]Bay N.Forming limits in hydromechanical deep drawing[J].Annals of the CIRP,1994,43(1):253-256
[5]Yang D Y,Kim J B,Wlee D.Investigation into manufacturing of very long cups by hydromechanical deep-drawing and ironing with controlled radial pressure[J].Annals of the CIRP,1995,44(1):255-258
[6]Yang D Y,Jung D W,Song I S,et al.Comparative investigation into implicit/explicit and iterative implicit/explicit schemes for the simulation of sheet-metal forming processes[J].Material Processing Technology,1995,50(1):39-53
[7]徐永超,陈宇,苑士剑.半球底筒形件充液拉深加载路径优化研究[J].哈尔滨工业大学学报,2008,40(7):1076-1080Xu Y C,Chen Y,Yuan S J.Loading path optimization of hydro-mechanical deep drawing of the cup with a semi-ball bottom[J].Journal of Harbin Institute of Technology,2008,40(7):1076-1080(in Chinese)
[8]Lang L H,Wang Y M,Xie Y S,et al.Pre-bulging effect during sheet hydroforming process of aluminum alloy box with unequal height and flat bottom[J].Transactions of Nonferrous Metals Society of China,2012,22(2):302-307
[9]Gorji A,Alavi-hashemi H,Bakhshi-jooybari M,et al.Investigation of hydrodynamic deep drawing for conical cylindrical cups[J].International Journal Advanced Manufacturing Technology,2011,56:915-927
[10]刘晓晶,徐永超,苑士剑.反胀压力对铝合金球底筒形件充液拉深过程的影响[J].塑性工程学报,2008,15(3):42-46Liu X J,Xu Y C,Yuan S J.The influence of inverse bulging pressure on the hydrodynamic deep drawing process of aluminium alloy cylindrical cups with a hemispherical bottom[J].Journal of Plasticity Engineering,2008,15(3):42-46(in Chinese)
[11]Kawka M,Olejnik L,Rosochowski A,et al.Simulation of wrinkling in sheet metal forming[J].J Materials Processing Technology,2001,109:283-289
[12]Vollertsen F.Processes Layout Avoiding Reverse Drawing Wrinkles in Hydroforming of Sheet Metal[J].Ann Crip,2002,52(1):203-208
[13]陈一哲,刘伟,苑士剑.薄板液压成形起皱预测及控制研究进展[J].机械工程学报,2016,52(4):20-27Chen Y Z,Liu W,Yuan S J.Research development on wrinkling prediction and suppression for sheet hydroforming of thin-walled deep drawing parts[J].Journal of Mechanical Engineering,2016,52(4):20-27(in Chinese)
[14]Liu X,Xu Y C,Yuan S J.Hydro-forming of aluminum alloy complex-shaped components[J].Transactions of Nonferrous Metals Society of China,2011,21(2):417-422
[15]孟宝,万敏,吴向东,等.板材充液拉深动态加载系统开发与应用[J].机械工程学报,2013 49(24):60-66Meng B,Wan M,Wu X D,et al.Development of dynamic loading system for sheet metal hydrodynamic deep drawing and its application[J].Journal of Plasticity Engineering,2013 49(24):60-66(in Chinese)