5A02铝合金薄壁管绕弯成形数值模拟及试验
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摘要
利用有限元分析软件Pam-stamp对5A02铝合金薄壁管的数控绕弯过程进行了数值模拟,研究了芯棒伸出量和弯管角度对管坯的壁厚减薄率、不圆度和回弹等的影响,并进行了数控绕弯成形试验。结果表明,随着伸出量的增长,壁厚减薄率呈指数式增长,不圆度以抛物线减小,且试验结果与模拟结果基本一致;管的回弹随弯管角度增大而增大。用最小二乘法拟合得到弯管回弹公式,并在弯管试验中得到理想的弯管效果。
The NC rotary-draw-bending process of 5 A02 aluminum alloy thin-walled tube was numerically simulated by using finite element analysis software Pam-stamp. The influences of mandrel extension and bending angle on the wall thickness thinning rate, non-circularity and springback of the tube blank were studied. And the NC rotary-draw-bending forming experiments were carried out. The results show that with the increase of the mandrel extension,the thinning rate of the wall thickness increases exponentially and the non-circularity decreases with parabola. Furthermore, the experimental results are approximately accordance with the simulation resuits. The springback of the tube increases with the increase of the bending angle. The springback formula of the bent tube was obtained by the least square method and the ideal bending effect was obtained in the bending test.
The NC rotary-draw-bending process of 5 A02 aluminum alloy thin-walled tube was numerically simulated by using finite element analysis software Pam-stamp. The influences of mandrel extension and bending angle on the wall thickness thinning rate, non-circularity and springback of the tube blank were studied. And the NC rotary-draw-bending forming experiments were carried out. The results show that with the increase of the mandrel extension,the thinning rate of the wall thickness increases exponentially and the non-circularity decreases with parabola. Furthermore, the experimental results are approximately accordance with the simulation resuits. The springback of the tube increases with the increase of the bending angle. The springback formula of the bent tube was obtained by the least square method and the ideal bending effect was obtained in the bending test.
引文
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[2]苑世剑,韩聪,王小松.空心变截面构件内高压成形工艺与装备[J].机械工程学报,2012,48(18):21-27.
[3] Ko觭M, Altan T.An overall review of the tube hydroforming(THF)technology[J].Journal of Materials Processing Technology,2001,108(3):384-393.
[4] Alaswad A, Benyounis K Y, Olabi A G.Tube hydroforming process:a reference guide[J].Materials&Design,2012,33(1):328-339.
[5]张帆,郎利辉,程鹏志,等.异形截面构件多工序充液成形工艺及过程优化[J].锻压技术,2014,39(3):42-46.
[6]蔡洋,刘强,王小松,等.内高压成形制备6063铝合金异形管件的壁厚分布及尺寸精度[J].中国有色金属学报,2015,25(9):2372-2380.
[7]卫原平.金属塑性成形过程的有限元数值模拟[D].上海:上海交通大学,1994.
[8]胡福泰,刘玉峰,黄学玲,等.管材与型材无模弯曲基本力学分析[J].锻压技术,1996(4):22-24.
[9]刘红,蒋兰芳,贾平平.弯管弯曲仿真中的芯棒结构建模[J].轻工机械,2015,33(4):27-30.
[10]李恒,杨合,詹梅,等.大口径薄壁小弯曲半径数控弯管有限元建模和试验[J].锻压技术,2006,31(5):136-139.
[11] Yang H, Li H, Zhan M.Friction role in bending behaviors of thin-walled tube in rotary-draw-bending under small bending radii[J].Journal of Materials Processing Technology,2010,210(15):2273-2284.
[12] Li H, Yang H, Yan J, et al.Numerical study on deformation behaviors of thin-walled tube NC bending with large diameter and small bending radius[J].Computational Materials Science,2009,45(4):921-934.
[13]张伟玮,韩聪,谢文才,等.管材弯曲回弹对内高压成形的影响及补偿方法[J].哈尔滨工业大学学报,2014,46(7):36-39.
[14]王光祥,杨合,李恒,等.工艺参数对薄壁数控弯管成形质量影响的试验研究[J].机械科学与技术,2005,24(8):995-998.
[15]王泽康,杨合,李恒,等.大口径316L不锈钢管数控弯曲回弹规律研究[J].材料科学与工艺,2012,20(4):49-54.
[16]陈一哲,刘伟,苑世剑.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):20-28.
[17] Liewald M, Wagner S.State-of-the-art of hydroforming tubes and sheets in Europe[J].Journal of Plasticity Engineering,2007,14:147-151.
[18]刘忠利,任建军,陶杰,等.汽车底盘纵梁多工步成形数值模拟及试验[J].塑性工程学报,2015,22(5):57-62.
[19]刘红,蒋兰芳,贾平平.弯管弯曲仿真中的芯棒结构建模[J].轻工机械,2015,33(4):27-30.