薄壁鋁合金封頭擋板輔助旋壓成形新工藝研究
發(fā)布時間：2018-07-21 11:25
【摘要】：旋壓是板料連續(xù)局部塑性成形方法,具有高質(zhì)、高效、節(jié)能、節(jié)材等優(yōu)點。但成形過程復(fù)雜,屬于大應(yīng)變、非線性變形問題,容易出現(xiàn)起皺和開裂問題。薄壁鋁合金封頭整體剛度較低,旋壓過程中更容易產(chǎn)生法蘭起皺缺陷,其成形性難以控制。因此如何改進薄壁鋁合金封頭的旋壓工藝,提高成形質(zhì)量成為研究熱點。本文設(shè)計了不同徑厚比的封頭特征零件,研究了封頭旋壓有限元建模方法,建立了成形質(zhì)量評價體系,提出了薄壁鋁合金封頭擋板輔助旋壓成形新工藝,對比研究了不同徑厚比條件下新工藝的優(yōu)勢,并討論了尺寸及主要工藝參數(shù)對成形質(zhì)量的影響。本文的主要工作內(nèi)容包括以下四點:(1)基于ABAQUS/Explicit平臺,研究了薄壁鋁合金封頭旋壓有限元建模方法,建立了包含壁厚均勻性和貼膜度的成形質(zhì)量評價體系;(2)針對傳統(tǒng)旋壓工藝繁瑣、壁厚不均的問題,提出了薄壁鋁合金封頭擋板輔助旋壓成形新工藝,通過在法蘭前方設(shè)置一剛性擋板,提高法蘭支承剛度,可實現(xiàn)特征薄壁封頭一道次普旋成形;(3)在此基礎(chǔ)上,對擋板輔助旋壓和預(yù)彎邊的先剪后普多道次旋壓兩種工藝進行了對比研究,發(fā)現(xiàn)新工藝得到的構(gòu)件壁厚均勻性明顯優(yōu)于傳統(tǒng)工藝,貼膜度也較傳統(tǒng)工藝好。隨著徑厚比的增大,薄壁結(jié)構(gòu)的弱剛性特征突出,傳統(tǒng)工藝需要增加道次數(shù)目來克服起皺,但新工藝仍然能夠一道次普旋成形,且徑厚比越大,新工藝對壁厚均勻性的改善作用越顯著;(4)研究了新工藝條件下尺寸參數(shù)(板料直徑)及主要工藝參數(shù)(進給率、旋輪圓角半徑和旋輪安裝角)對封頭成形質(zhì)量的影響規(guī)律,通過合理的參數(shù)優(yōu)化配置,可以在提高壁厚均勻性的同時改善構(gòu)件貼膜情況,實現(xiàn)零件的優(yōu)質(zhì)高效成形;
[Abstract]:Spinning is a continuous local plastic forming method for sheet metal, which has the advantages of high quality, high efficiency, energy saving and material saving. However, the forming process is complex and belongs to the problem of large strain and nonlinear deformation, so it is easy to wrinkle and crack. The integral stiffness of thin-walled aluminum alloy head is low, and the flange wrinkling defect is more easily produced in spinning process, and its formability is difficult to control. Therefore, how to improve the spinning process of thin-walled aluminum alloy head and improve the forming quality has become a research hotspot. In this paper, the characteristic parts of the head with different ratio of diameter to thickness are designed, the finite element modeling method of the head spinning is studied, the evaluation system of forming quality is established, and a new technology of the thin wall aluminum alloy head baffle assisted spinning forming is put forward. The advantages of the new process under different ratio of diameter to thickness are studied, and the influence of the size and main process parameters on the forming quality is discussed. The main work of this paper includes the following four points: (1) based on Abaqus / explicit platform, the finite element modeling method of thin-walled aluminum alloy head spinning is studied, and the forming quality evaluation system including wall thickness uniformity and film adhesion is established. (2) the traditional spinning process is cumbersome. The problem of uneven wall thickness is discussed. A new technology of auxiliary spinning forming for thin-walled aluminum alloy head baffle is put forward. By setting a rigid baffle in front of the flange, the supporting stiffness of the flange can be improved, and the characteristic thin-walled head can be rotated together. (3) on this basis, A comparative study was made between the two processes of baffle assisted spinning and prebending edge cutting and then prebending. It was found that the uniformity of wall thickness of the components obtained by the new technology was obviously better than that of the traditional process, and the film sticking degree was better than the traditional process. With the increase of the ratio of diameter to thickness, the weak rigidity of thin-walled structure is prominent. The traditional process needs to increase the number of passes to overcome the wrinkle, but the new process can still be formed by a secondary rotation, and the larger the ratio of diameter to thickness, the greater the ratio of diameter to thickness. (4) the influence of dimension parameters (sheet diameter) and main process parameters (feed rate, rotary wheel radius and wheel mounting angle) on the forming quality of the head is studied. By optimizing the parameters, we can improve the uniformity of the wall thickness and the case of the component film, and realize the high quality and high efficiency forming of the parts.
【學(xué)位授予單位】：上海交通大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2015
【分類號】：TG306
本文編號：2135365
[Abstract]:Spinning is a continuous local plastic forming method for sheet metal, which has the advantages of high quality, high efficiency, energy saving and material saving. However, the forming process is complex and belongs to the problem of large strain and nonlinear deformation, so it is easy to wrinkle and crack. The integral stiffness of thin-walled aluminum alloy head is low, and the flange wrinkling defect is more easily produced in spinning process, and its formability is difficult to control. Therefore, how to improve the spinning process of thin-walled aluminum alloy head and improve the forming quality has become a research hotspot. In this paper, the characteristic parts of the head with different ratio of diameter to thickness are designed, the finite element modeling method of the head spinning is studied, the evaluation system of forming quality is established, and a new technology of the thin wall aluminum alloy head baffle assisted spinning forming is put forward. The advantages of the new process under different ratio of diameter to thickness are studied, and the influence of the size and main process parameters on the forming quality is discussed. The main work of this paper includes the following four points: (1) based on Abaqus / explicit platform, the finite element modeling method of thin-walled aluminum alloy head spinning is studied, and the forming quality evaluation system including wall thickness uniformity and film adhesion is established. (2) the traditional spinning process is cumbersome. The problem of uneven wall thickness is discussed. A new technology of auxiliary spinning forming for thin-walled aluminum alloy head baffle is put forward. By setting a rigid baffle in front of the flange, the supporting stiffness of the flange can be improved, and the characteristic thin-walled head can be rotated together. (3) on this basis, A comparative study was made between the two processes of baffle assisted spinning and prebending edge cutting and then prebending. It was found that the uniformity of wall thickness of the components obtained by the new technology was obviously better than that of the traditional process, and the film sticking degree was better than the traditional process. With the increase of the ratio of diameter to thickness, the weak rigidity of thin-walled structure is prominent. The traditional process needs to increase the number of passes to overcome the wrinkle, but the new process can still be formed by a secondary rotation, and the larger the ratio of diameter to thickness, the greater the ratio of diameter to thickness. (4) the influence of dimension parameters (sheet diameter) and main process parameters (feed rate, rotary wheel radius and wheel mounting angle) on the forming quality of the head is studied. By optimizing the parameters, we can improve the uniformity of the wall thickness and the case of the component film, and realize the high quality and high efficiency forming of the parts.
【學(xué)位授予單位】：上海交通大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2015
【分類號】：TG306
【參考文獻】
相關(guān)期刊論文 前2條
1 高西成,康達昌,孟曉峰;薄壁筒收口旋壓過程的數(shù)值模擬[J];塑性工程學(xué)報;1999年04期
2 宋曉飛;詹梅;蔣華兵;李甜;楊合;;鋁合金大型復(fù)雜薄壁殼體多道次旋壓缺陷形成機理[J];塑性工程學(xué)報;2013年01期
，本文編號：2135365
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