管件电磁胀形过程中的材料变形性能问题与电磁力加载方案
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摘要
管件电磁胀形因其在轻质合金加工领域具有明显优势而得到广泛研究。传统电磁胀形过程中,存在管件壁厚减小、轴向变形非均匀等问题,制约了这一技术的发展。提出采用径向电磁力与轴向电磁力双向加载的施力方式,构建轴向压缩式管件电磁冲胀形方法解决壁厚减薄问题;仿真数据显示,因为轴向压缩,管件壁厚减薄量由最初的15.05%降低至9.65%。进一步地,提出采用凹型线圈削弱管件中部电磁力以提高管件成形质量的方法;算例中,采用凹型线圈时最大变形区域为36mm,"凹型"分布的径向电磁力可有效改善管件轴向变形非均匀问题。显然,电磁力加载方案的改进能有效解决管件电磁胀形存在的问题,推动电磁成形技术工业化应用进程。
Electromagnetic tube expansion has been extensively studied for its obvious advantages in lightweight alloy processing.Due to the reduction of wall thickness and the non-uniform deformation in axial direction,the development of the existing electromagnetic tube expansion has been restricted.In this paper,the method of electromagnetic tube expansion with axial compression is proposed,with which both the radial and the axial electromagnetic force are applied to decrease the reduction of wall thickness.The simulation results show that the reduction of wall thickness is reduced from 15.05% to 9.65%.Furthermore,the method of electromagnetic tube expansion with concave coil to weaken the electromagnetic force in the middle part is proposed to improve the tube forming performance.In the simulation,the maximum deformation is 36 mm,and it is obvious that the radial electromagnetic force produced by "concave" coil can effectively solve the problem of non-uniform tube deformation.The improvement of electromagnetism force loading can effectively solve problems in electromagnetic tube expansion and promote its industrial application.
Electromagnetic tube expansion has been extensively studied for its obvious advantages in lightweight alloy processing.Due to the reduction of wall thickness and the non-uniform deformation in axial direction,the development of the existing electromagnetic tube expansion has been restricted.In this paper,the method of electromagnetic tube expansion with axial compression is proposed,with which both the radial and the axial electromagnetic force are applied to decrease the reduction of wall thickness.The simulation results show that the reduction of wall thickness is reduced from 15.05% to 9.65%.Furthermore,the method of electromagnetic tube expansion with concave coil to weaken the electromagnetic force in the middle part is proposed to improve the tube forming performance.In the simulation,the maximum deformation is 36 mm,and it is obvious that the radial electromagnetic force produced by "concave" coil can effectively solve the problem of non-uniform tube deformation.The improvement of electromagnetism force loading can effectively solve problems in electromagnetic tube expansion and promote its industrial application.
引文
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[2]Cao Quanliang,Han Xiaotao,Lai Zhipeng,et al.Effects of current frequency on electromagnetic sheet metal forming process[J].IEEE Transactions on Applied Superconductivity,2013,24(3):1-4.
[3]黎镇浩,曹全梁,赖智鹏,等.电流丝法在电磁成形线圈电流和工件电磁力计算中的应用研究[J].电工技术学报,2018,33(18):4181-4190.Li Zhenhao,Cao Quanliang,Lai Zhipeng,et al.Application of current filament method on the calculation of current and force in electromagnetic forming[J].Transactions on China Electrotechnical Society,2018,33(18):4181-4190.
[4]Chu Y Y,Lee R S,Psyk V,et al.Determination of the flow curve at high strain rates using electromagnetic punch stretching[J].Journal of Materials Processing Technology,2012,212(6):1314-1323.
[5]Qiu Li,Xiao Yao,Deng Changzheng,et al.Electromagnetic-structural analysis and improved loose coupling method in electromagnetic forming process[J].International Journal of Advanced Manufacturing Technology,2017,89(1-4):1-10.
[6]Kamal M.A uniform pressure electromagnetic actuator for forming flat sheets[J].Journal of Manufacturing Science&Engineering,2007,129(2):369-379.
[7]Golowin S,Kamal M,Shang J,et al.Application of a uniform pressure actuator for electromagnetic processing of sheet metal[J].Journal of Materials Engineering&Performance,2007,16(4):455-460.
[8]Weddeling C,Hahn M,Daehn G S,et al.Uniform pressure electromagnetic actuator-an innovative tool for magnetic pulse welding[C]//Proceedings of the International Conference on Manufacturing of Lightweight Components,2014,18:156-161.
[9]Kiliclar Y,Demir O K,Vladimirov I N,et al.Combined simulation of quasi-static deep drawing and electromagnetic forming by means of a coupled damage-viscoplasticity model at finite strains[C]//The 5th International Conference on High Speed Forming,Dortmund,Germany,2012:325-333.
[10]Cui Xiaohui,Mo Jianhua,Li J J,et al.Electromagnetic incremental forming(EMIF):a novel aluminum alloy sheet and tube forming technology[J].Journal of Materials Processing Technology,2014,214(2):409-427.
[11]Cui Xiaohui,Mo Jianhua,Li J J,et al.Produce a large aluminium alloy sheet metal using electromagnetic-incremental(EM-IF)forming method:experiment and numerical simulation[C]//The 5th International Conference on High Speed Forming,Dortmund,Germany,2012:59-70.
[12]Li Liang,Han Xiaotao,Peng Tao,et al.Spacetime-controlled multi-stage pulsed magnetic field forming and manufacturing technology[C]//The 5th International Conference on High Speed Forming,Dortmund,Germany,2012:53-58.
[13]Li Liang,Han Xiaotao,Cao Quanliang,et al.Development of space-time-controlled multi-stage pulsed magnetic field forming and manufacturing technology at the WHMFC[C]//The 6th International Conference on High Speed Forming,Daejeon,Korea,2014:353-362.
[14]丘明,饶双全,诸嘉慧,等.基于磁-路耦合分析法的高温超导环形储能磁体电磁优化设计[J].电工技术学报,2016,31(增刊2):176-182.Qiu Ming,Rao Shuangquan,Zhu Jiahui,et al.Electromagnetic optimization design of a toroidal HTS-SMES magnet using magneto-circuit coupling analysis methoed[J].Transactions on China Electrotechnical Society,2016,31(S2):176-182.
[15]朱英伟,雷勇,周群,等.径向磁场与环向电流作用的电磁发射模式[J].电工技术学报,2016,31(18):54-58.Zhu Yingwei,Lei Yong,Zhou Qun,et al.Multipole field electromagnetic launch model based on radial magnetic field interact with loop eddy current[J].Transactions on China Electrotechnical Society,2016,31(18):54-58.
[16]Cao Quanliang,Lai Zhipeng,Xiong Qi,et al.Electromagnetic attractive forming of sheet metals by means of a dual-frequency discharge current:design and implementation[J].International Journal of Advanced Manufacturing Technology,2016,90(1-4):1-8.
[17]Cao Quanliang,Han Xiaotao,Lai Zhipeng,et al.Analysis and reduction of coil temperature rise in electromagnetic forming[J].Journal of Materials Processing Technology,2015,225:185-194.
[18]Qiu Li,Yu Yijie,Wang Ziwei,et al.Analysis of electromagnetic force and deformation behavior in electromagnetic tube expansion with concave coil based on finite element method[J].IEEE Transactions on Applied Superconductivity,2018,28(3):1-5.
[19]邱立.径向与轴向双向加载式金属管件电磁成形方法及装置:中国,201310336158.1[P].2015-01-07.
[20]邱立,余一杰,熊奇,等.一种柔性电磁力加载式金属管件电磁成形装置及方法:中国,201710240757.1[P].2017-07-14.