镁合金管材热态内压成形失稳行为研究
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摘要
管材热态内压成形是将模具和管材预热到温热状态,然后按照给定的加载路径把管材成形为所需形状的零件。它可以实现室温塑性低比强度高的轻质材料管材的成形,从而进一步减轻结构质量。本文建立了AZ31B镁合金管材在150℃~300℃温度范围内的本构模型,提出并建立了预测管材轴向起皱时临界应力的理论模型,研究了AZ31B镁合金管材在起皱过程中的应力应变状态、皱纹几何形状和壁厚分布变化规律,研究了温度、截面预成形和轴向补料预成形对AZ31B镁合金管材破裂的影响规律,分析了在管材热态内压成形过程中使用起皱件作为预成形坯及采用差温成形非均匀壁厚镁合金管材的变形机理。
从室温至300℃温度区间、应变速率从0.001s-1到0.1s-1的条件下对AZ31B镁合金无缝挤压管材进行了轴向拉伸试验。结果表明:随温度升高或应变速率降低,镁合金管材的屈服强度和抗拉强度降低,总延伸率增加,均匀延伸率先增大后减小,在175℃或在0.01s-1的应变速率下达到相对最大值。采用Beckofen方程拟合得到了AZ31B镁合金管材的本构方程,该方程可体现镁合金管材流动应力随温度升高而下降的趋势。
建立了管材在内高压成形过程中发生轴对称起皱失稳时临界轴向应力的数学模型,该模型能综合反映内压及应力比、管材几何尺寸及材料性能、温度场等对临界起皱应力的影响。参数分析的结果表明:当临界起皱应力函数在可发生起皱的应力比上限值处的偏导数为正时,临界起皱应力将随应力比的增大或内压的减小而增大,当该偏导数为负时,临界起皱应力将先减小后增大。当屈服强度和简化模量的相对变化量为负时,临界起皱应力将随之减小,当该相对变化量为正时,临界起皱应力将随之增大。
研究了不同内压、不同补料量和不同温度下AZ31B镁合金管材起皱过程中的皱纹形状和几何尺寸、起皱位置和皱纹数量、壁厚分布等的变化规律,分析了起皱区域应力应变状态的变化,研究了在管材热态内压成形过程中使用起皱作为预成形坯成形大膨胀率零件的变形机理。结果表明:当内压与屈服强度比小于1 3倍厚径比时,初始屈服时管材壁厚有增加的趋势,反之,则管材壁厚有减薄的趋势。对于给定的内压与屈服强度比,温度越高,则壁厚增加的程度越小。随补料量的增加,皱纹上各点的应力轨迹在平面应力状态屈服轨迹上对应环向应变增加、轴向应变减小、厚向应变先增大后减小的过程。随补料量的增大,皱纹的外径不断增大、宽度不断减小且皱纹向中间移动。随内压的增大或温度的升高,皱纹的外径和宽度均不断增大且皱纹向中间移动。此外,温度越高、内压越大或补料量越大,起皱后管件壁厚整体的减薄越严重,壁厚分布越不均匀。采用起皱预成形坯是管材热态内压成形过程中成形大膨胀率零件的有效方法。如果材料的n值越大,或终成形零件相对于原始管材的最大膨胀率越大,可用更小的补料量来制取起皱预成形坯。
研究了温度、截面预成形和轴向补料对AZ31B镁合金管材破裂失稳的影响,揭示了镁合金管材破裂压力和极限胀形率的变化规律,分析了采用差温温度场成形初始壁厚非均匀的镁合金管材的变形机理。结果表明:随着温度的升高,管材的初始屈服内压和胀破压力不断下降;管材发生破裂时的极限胀形率先增大后减小。随着胀形前对管材的径向下压量增大,管材的极限胀形率和胀破压力不断下降。随着胀形前管材轴向补料量的增大,管材破裂时的极限胀形率不断增大,有利于大变形量零件的成形。通过在初始壁厚较大的位置设置较高温度,在初始壁厚较小的位置设置较低温度,可以使管材的壁厚在胀形过程中更趋均匀。
Warm tube hydroforming is an advanced process for forming a tubular part by a designed loading path in the warm condition. Due to the improvement of formability at elvated temperature, light-weight metal tubes with high specific strength but low formability can be formed by this method. Therefore, the part weight can be reduced further. In this dissertation, the constitutive equation of AZ31B magnesium alloy tube among the temperature rangs of 150℃and 300℃was built based on experimental results. For forecasting the critical wrinkling stress of a tube, the theoretical model was proposed. The principles of stress states and strain states, wrinkles’shape and wall thickness of an AZ31B magnesium alloy tube during its wrinkling process were investigated. Influences of temperature, cross-section preforming and axial feeding preforming on the bursting of an AZ31B magnesium alloy tube were researched. Moreover, the feasibility about taking wrinkled parts as preforms and the feasibility about forming a tube with a nonuniform initial wall thickness in differential temperature fields were also analyzed.
Axial tensile tests for a seamless AZ31B alloy tube were conducted when the processing temperature changed from 20℃to 300℃, and strain rate changed from 0.001s-1 to 0.1s-1. Results showed that the yielding strength and the tensile strength decreased as the processing temperature increased or the strain rate decreased. The total elongation increased, but the uniform elongation first increased and then decreased. The maximum uniform elongation was obtained at the condition of 175℃or 0.01s-1. Contitutive equation of the AZ31B magnesium alloy tube was obtained by fitting multiple regression Beckofen equation. The phenonman of work hardening can be reflected by this equation.
Critical stress for the onset of axisymmetric wrinkling in tube hydroforming was derived. Influences of internal pressure and stress ratio, the geometries and properties of a tube and temperature field on the critical wrinkling stress were analyzed. Results showed that the critical wrinkling stress increased as the stress ratio increased when the partial derivative of the model function was positive. The critical wrinkling stress first deceased and then increased as the stress ratio increased when the partial derivative of the model function was negative. The critical wrinkling stress would decrease if the relative value between the yielding strength and the reduced modulus was negative. Otherwise, it would increase.
Variety of wrinkles’shape and demension, wrinkling location and quantity, wall tickness distribution and stress and strain states during wirnkling were researched at different internal pressures, temperatures and feedings. The feasibility about taking wrinkled parts as preforms was analyzed. Results showed that the wall thickness in the initial yielding state would increase if the ratio of internal pressure to yielding strength was less than 1 3 times the thickness radius ratio. Otherwise, the wall thickness at initial yielding state would decrease. The increasing magnitude of the tube was lower if the processing temperature was higher. As feeding increased, the circumferential strain increased, but the axial strain decreased. The thickness strain first increased and then decreased. The outer radius of the wrinkles increased but the width decreased. The wrinkles moved vis-a-vis. As internal pressure or temperature was elevated, both the outer radius and the width of the wrinkles increased and the wrinkles also move vis-a-vis. In addition, it was a reasonable method to form parts with large expansion ratio by taking wrinkled parts as preforms.
Influences of temperature, cross-section preforming and axial feeding preforming on the bursting of an AZ31B magnesium alloy tube were investigated. The feasibility about forming a tube with a nonuniform initial wall thickness in a differential temperature field was analyzed. Results showed that the internal pressure for initial yielding and bursting decreased as the processing temperature increased. The maximum expansion ratio first increased and then decreased. As the flatten displacement increased, both the maximum expansion ratio and the bursting internal pressure decreased. As the axial feeding increased before bulging, the maximum expansion ratio increased which was good for forming parts with large expansion ratio. Besides, the tube wall thickness could be changed more uniform if the tube section with higher initial wall thickness was at higher temperature.
从室温至300℃温度区间、应变速率从0.001s-1到0.1s-1的条件下对AZ31B镁合金无缝挤压管材进行了轴向拉伸试验。结果表明:随温度升高或应变速率降低,镁合金管材的屈服强度和抗拉强度降低,总延伸率增加,均匀延伸率先增大后减小,在175℃或在0.01s-1的应变速率下达到相对最大值。采用Beckofen方程拟合得到了AZ31B镁合金管材的本构方程,该方程可体现镁合金管材流动应力随温度升高而下降的趋势。
建立了管材在内高压成形过程中发生轴对称起皱失稳时临界轴向应力的数学模型,该模型能综合反映内压及应力比、管材几何尺寸及材料性能、温度场等对临界起皱应力的影响。参数分析的结果表明:当临界起皱应力函数在可发生起皱的应力比上限值处的偏导数为正时,临界起皱应力将随应力比的增大或内压的减小而增大,当该偏导数为负时,临界起皱应力将先减小后增大。当屈服强度和简化模量的相对变化量为负时,临界起皱应力将随之减小,当该相对变化量为正时,临界起皱应力将随之增大。
研究了不同内压、不同补料量和不同温度下AZ31B镁合金管材起皱过程中的皱纹形状和几何尺寸、起皱位置和皱纹数量、壁厚分布等的变化规律,分析了起皱区域应力应变状态的变化,研究了在管材热态内压成形过程中使用起皱作为预成形坯成形大膨胀率零件的变形机理。结果表明:当内压与屈服强度比小于1 3倍厚径比时,初始屈服时管材壁厚有增加的趋势,反之,则管材壁厚有减薄的趋势。对于给定的内压与屈服强度比,温度越高,则壁厚增加的程度越小。随补料量的增加,皱纹上各点的应力轨迹在平面应力状态屈服轨迹上对应环向应变增加、轴向应变减小、厚向应变先增大后减小的过程。随补料量的增大,皱纹的外径不断增大、宽度不断减小且皱纹向中间移动。随内压的增大或温度的升高,皱纹的外径和宽度均不断增大且皱纹向中间移动。此外,温度越高、内压越大或补料量越大,起皱后管件壁厚整体的减薄越严重,壁厚分布越不均匀。采用起皱预成形坯是管材热态内压成形过程中成形大膨胀率零件的有效方法。如果材料的n值越大,或终成形零件相对于原始管材的最大膨胀率越大,可用更小的补料量来制取起皱预成形坯。
研究了温度、截面预成形和轴向补料对AZ31B镁合金管材破裂失稳的影响,揭示了镁合金管材破裂压力和极限胀形率的变化规律,分析了采用差温温度场成形初始壁厚非均匀的镁合金管材的变形机理。结果表明:随着温度的升高,管材的初始屈服内压和胀破压力不断下降;管材发生破裂时的极限胀形率先增大后减小。随着胀形前对管材的径向下压量增大,管材的极限胀形率和胀破压力不断下降。随着胀形前管材轴向补料量的增大,管材破裂时的极限胀形率不断增大,有利于大变形量零件的成形。通过在初始壁厚较大的位置设置较高温度,在初始壁厚较小的位置设置较低温度,可以使管材的壁厚在胀形过程中更趋均匀。
Warm tube hydroforming is an advanced process for forming a tubular part by a designed loading path in the warm condition. Due to the improvement of formability at elvated temperature, light-weight metal tubes with high specific strength but low formability can be formed by this method. Therefore, the part weight can be reduced further. In this dissertation, the constitutive equation of AZ31B magnesium alloy tube among the temperature rangs of 150℃and 300℃was built based on experimental results. For forecasting the critical wrinkling stress of a tube, the theoretical model was proposed. The principles of stress states and strain states, wrinkles’shape and wall thickness of an AZ31B magnesium alloy tube during its wrinkling process were investigated. Influences of temperature, cross-section preforming and axial feeding preforming on the bursting of an AZ31B magnesium alloy tube were researched. Moreover, the feasibility about taking wrinkled parts as preforms and the feasibility about forming a tube with a nonuniform initial wall thickness in differential temperature fields were also analyzed.
Axial tensile tests for a seamless AZ31B alloy tube were conducted when the processing temperature changed from 20℃to 300℃, and strain rate changed from 0.001s-1 to 0.1s-1. Results showed that the yielding strength and the tensile strength decreased as the processing temperature increased or the strain rate decreased. The total elongation increased, but the uniform elongation first increased and then decreased. The maximum uniform elongation was obtained at the condition of 175℃or 0.01s-1. Contitutive equation of the AZ31B magnesium alloy tube was obtained by fitting multiple regression Beckofen equation. The phenonman of work hardening can be reflected by this equation.
Critical stress for the onset of axisymmetric wrinkling in tube hydroforming was derived. Influences of internal pressure and stress ratio, the geometries and properties of a tube and temperature field on the critical wrinkling stress were analyzed. Results showed that the critical wrinkling stress increased as the stress ratio increased when the partial derivative of the model function was positive. The critical wrinkling stress first deceased and then increased as the stress ratio increased when the partial derivative of the model function was negative. The critical wrinkling stress would decrease if the relative value between the yielding strength and the reduced modulus was negative. Otherwise, it would increase.
Variety of wrinkles’shape and demension, wrinkling location and quantity, wall tickness distribution and stress and strain states during wirnkling were researched at different internal pressures, temperatures and feedings. The feasibility about taking wrinkled parts as preforms was analyzed. Results showed that the wall thickness in the initial yielding state would increase if the ratio of internal pressure to yielding strength was less than 1 3 times the thickness radius ratio. Otherwise, the wall thickness at initial yielding state would decrease. The increasing magnitude of the tube was lower if the processing temperature was higher. As feeding increased, the circumferential strain increased, but the axial strain decreased. The thickness strain first increased and then decreased. The outer radius of the wrinkles increased but the width decreased. The wrinkles moved vis-a-vis. As internal pressure or temperature was elevated, both the outer radius and the width of the wrinkles increased and the wrinkles also move vis-a-vis. In addition, it was a reasonable method to form parts with large expansion ratio by taking wrinkled parts as preforms.
Influences of temperature, cross-section preforming and axial feeding preforming on the bursting of an AZ31B magnesium alloy tube were investigated. The feasibility about forming a tube with a nonuniform initial wall thickness in a differential temperature field was analyzed. Results showed that the internal pressure for initial yielding and bursting decreased as the processing temperature increased. The maximum expansion ratio first increased and then decreased. As the flatten displacement increased, both the maximum expansion ratio and the bursting internal pressure decreased. As the axial feeding increased before bulging, the maximum expansion ratio increased which was good for forming parts with large expansion ratio. Besides, the tube wall thickness could be changed more uniform if the tube section with higher initial wall thickness was at higher temperature.
引文
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56 A. Mwembela, E. B. Konopleva, H. J. McQueen. Scripta Materialia. 1997, 37:1789-1795
57王忠堂,张士宏,齐广霞,王芳,李艳娟. AZ31镁合金热变形本构方程.中国有色金属学报. 2008, 18(11):1977-1982
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63 F. Dohmann, C. Hartl. Tube hydroforming—research and practical application. JMater Process Technol, 1997, 71(1): 174-186
64 F. Dohmann, C. Hartl. Hydroforming components for automotive applications.The Fabricator February, 1998, 28(2): 30-38
65 J.F. Lin, SJ. Yuan. Influence of internal pressure on hydroforming of doublehandles crankshaft. Mater. Sci. Eng., A. 2009, 499(1): 208-211
66苑世剑,王小松.内高压成形机理研究及其应用.机械工程学报. 2002, 38(12):12-15
67 S. J. Yuan, G. Liu, X. R. Huang, X. S. Wang, W. C. Xie and Z. R. Wang.Hydroforming of typical hollow components. J Mater Process Technol, 2004, 151(1-3): 203-207
68苑世剑.现代液压成形技术.北京:国防工业出版社, 2009
69 SJ. Yuan, C. Han, X.S. Wang. Hydroforming of automotive structuralcomponents with rectangular-sections. Int J Mach Tool Manu, 2006, 46(11): 1201-1206
70苑世剑,何祝斌,刘钢.轻合金热态液力成形技术.锻压技术. 2005, (6): 76-77
71苑世剑,李洪洋,戴昆,郎利辉,王仲仁.轻量化结构内高压成形技术.材料科学与工艺.1999, 17:139-142
72 Vollertsen E Hydrofornung of alununum alloys using heated oil. 9th InternationalConference on Sheet Metal. Leuven.2001
73 Vollertsen E Challenges and chances of hydrofornung of alununum alloys.Chinese-Germany ultralight symposium 19th-20th. Beijing, China, 2001:71-79
74 Siegert K, Jager S, Vulcan. M, Banabic D. An analytical approach ofsuperplastic bulging of magnesium sheet metal. ESAFORM 2003 conference, Salerno, 2003:163-167
75 Siegert K, Jager S.Vulcan M. Pneumatic bulging of magneaum AZ31 sheetmetal at elevated temperatures. Annals of the CIRP .2003.(l):241-244
76 Siegert K, Jager S. Warm forming of magneaum sheets. InternationalConference "New Developments in Sheet Metal Forming". Stuttgart. Germany. 2004: 11-12
77 Klaus Siegert, Markus Haussermann, Bruno Losch, et al. Recent developmentsin hydroforming technology. J Mater Process Technol. 2000, 98: 251-258
78 Mult E H. Geiger M. Sheet and Tube Hydroforming at Elevated Temperatures.International Conference on Hydroforming. Fellbach-Germany. on October, 28th to 29th, 2003: 259-278
79 Novotny S. Geiger M. Process design for hydroforming of light-weight metalsheets at elevated temperatures. J Mater Process Technol. 2003. 138:594-599
80 Vollertsen F. Hydroforming of aluminum alloys using heated oil. 9thInternational Conference on Sheet Metal. Leuven .2001
81 The thirdfrontier company, wright Capital Project Fund, Proposal Abstract[EB/OL]. http://www.thirdfrontier. com/pdf/WCPF _ proposal_abstracts pdf, 2004
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