5A06铝合金薄壁球形封头高温气胀成形工艺研究
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摘要
以5A06铝合金薄壁球形封头为研制对象,针对钣金工艺加工瓶颈和一步气胀成形减薄过大问题,开展预先热拉深-高温气胀成形工艺研究。利用有限元进行数值模拟分析,研究了预成形、气压加载速率对壁厚分布均匀性的影响,确定预成形和终成形优化方案,设计预成形和终成形模具,采用预拉深-高温气胀成形工艺试制5A06铝合金薄壁球形封头。结果表明,增加预成形后,球形封头最大减薄率从48.7%减小到24%,气压加载速度过大或过小对成形均有不利影响。在460～480℃温度下进行试验,加载氩气至1MPa,保压5min,成功制备出了5A06铝合金薄壁球形封头,封头表面质量好,成形精度高,型面与样板间隙小于0.2mm,封头壁厚在1.16～1.52mm之间,符合壁厚不低于1.1mm的要求。
Taking 5 A06 aluminum alloy thin wall spherical head as the research object, aiming at the bottleneck of the sheet metal processing and the problem of over-slimming in one-step gas bulging forming, the pre-heat drawing-high temperature gas bulging forming process was studied. The finite element method was used for numerical simulation analysis to study the effect of preforming and pressure loading rate on the uniformity of wall thickness distribution. By determining the optimal solution for preforming and final forming and designing preforming and final forming dies, the5 A06 aluminum alloy thin wall spherical heads were trial-manufactured by pre-heat drawing-high temperature gas bulging forming process. The results show that the maximum thinning rate of the spherical head decreases from 48.7% to24% after the preforming is applied, and too large or too small air pressure loading speed has an adverse effect on the forming. The 5 A06 aluminum alloy thin wall spherical head was successfully prepared at temperature of 460～480℃.Argon gas was loaded to 1 MPa and maintained for 5 minutes. The surface quality of the head is good and the forming accuracy is high. The gap between the surface and the template is less than 0.2 mm. The wall thickness of the head is between 1.16 mm and 1.52 mm, which meets the requirement of a wall thickness of not less than 1.1 mm.
Taking 5 A06 aluminum alloy thin wall spherical head as the research object, aiming at the bottleneck of the sheet metal processing and the problem of over-slimming in one-step gas bulging forming, the pre-heat drawing-high temperature gas bulging forming process was studied. The finite element method was used for numerical simulation analysis to study the effect of preforming and pressure loading rate on the uniformity of wall thickness distribution. By determining the optimal solution for preforming and final forming and designing preforming and final forming dies, the5 A06 aluminum alloy thin wall spherical heads were trial-manufactured by pre-heat drawing-high temperature gas bulging forming process. The results show that the maximum thinning rate of the spherical head decreases from 48.7% to24% after the preforming is applied, and too large or too small air pressure loading speed has an adverse effect on the forming. The 5 A06 aluminum alloy thin wall spherical head was successfully prepared at temperature of 460～480℃.Argon gas was loaded to 1 MPa and maintained for 5 minutes. The surface quality of the head is good and the forming accuracy is high. The gap between the surface and the template is less than 0.2 mm. The wall thickness of the head is between 1.16 mm and 1.52 mm, which meets the requirement of a wall thickness of not less than 1.1 mm.
引文
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2罗征志,曾京,方华伟.封头坯料拼焊成形焊接残余应力分析[J].机械工程学报,2013,49(10):127~133
3姜桂荣.热旋封头工艺的研究与开发[J].热加工工艺,2003(2):32~33
4 Zheng Kailun,Politis D J,Wang Liliang,et al.A review on forming techniques for manufacturing lightweight complex-shaped aluminium panel components[J].International Journal of Lightweight Materials&Manufacture,2018
5毕宝鹏,王勇.5A06铝合金板材超塑气胀成形数值模拟[J].精密成形工程,2014(6):99~103
6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
7 Aksenov S A,Chumachenko E N,Kolesnikov A V,et al.Determination of Optimal Conditions for Gas Forming of Aluminum Sheets[J].Procedia Engineering,2014,81(81):1017~1022
8 Aoura Y,Ollivier D,Ambari A,et al.Determination of material parameters for 7475 Al alloy from bulge forming tests at constant stress[J].Journal of Materials Processing Technology,2004,145(3):352~359
9丁桦,张凯锋.材料超塑性研究的现状与发展[J].中国有色金属学报,2004,14(7):1059~1067
10闫洪华,张凯锋.细晶5083铝合金非等温拉深工艺研究[J].热加工工艺,2010,39(5):17~20
11蒋少松,张凯锋,吴海峰,等.控制厚度分布的变摩擦正反向超塑成形[J].哈尔滨工业大学学报,2010,42(2):249~253
12 Luo Y,Luckey S G,Friedman P A,et al.Development of an advanced superplastic forming process utilizing a mechanical pre-forming operation[J].International Journal of Machine Tools&Manufacture,2008,48(12-13):1509~1518
13 Luckey G Jr,Friedman P,Weinmann K.Design and experimental validation of a two-stage superplastic forming die[J].Journal of Materials Processing Technology,2009,209(4):2152~2160
14 Lang Lihui,Danckert J,Nielsen K B.Investigation into the effect of pre-bulging during hydromechanical deep drawing with uniform pressure onto the blank[J].International Journal of Machine Tools&Manufacture,2004,44(6):649657
15 Fereshteh-Saniee F,Fakhar N,Asgari M,et al.A new experimentalnumerical approach for studying the effects of gas pressure profile on superplastic forming characteristics of Al-Mg5.6 alloy[J].International Journal of Advanced Manufacturing Technology,2016:1~10