預脹對鋁合金充液拉深影響的數值模擬研究
發(fā)布時間：2018-10-21 11:22
【摘要】：目前，汽車輕量化對節(jié)約能源，減少環(huán)境污染等方面越來越受到關注，那么鋁合金汽車零部件也就越來越被廣泛的應用，但鋁合金板材比鋼板的成形性低很多，而且汽車覆蓋件的形狀復雜，用傳統(tǒng)的冷沖壓成形工藝很容易出現褶皺和拉裂等質量缺陷。 板材充液拉深成形是傳統(tǒng)沖壓成型工藝和液壓成形工藝的結合，在成形過程中，凸模接觸板料，在液室壓力的作用使板料成形。板料液壓拉深成形比傳統(tǒng)的拉深工藝具備更多的優(yōu)點，比如可獲得更高的拉深比，更好的表面質量和較高的尺寸精度。預脹是充液拉深成形過程之前液室預先增加壓力，使板料預先脹形形成軟拉延筋的成形方式。軟拉延筋的形成可增加板料成形的穩(wěn)定性和獲得更好零件質量。 本文以鋁合金異形底盒形件和汽車油底盒為研究對象，針對它們的零件形狀進行成形工藝分析，采用預脹成形與充液拉深成形工藝相結合的新工藝進行零件的成形，并應用有限元模擬軟件Dynaform5.7.1對鋁合金異形底盒形件與汽車油底盒進行有限元模擬。 對鋁合金異形底盒形件和汽車油底盒成形結果進行分析，總結預脹壓力、預脹高度、液室壓力和壓邊間隙等參數對零件成形的影響規(guī)律。由于汽車油底盒形狀復雜，，板料成形時應力應變分布極為復雜，傳統(tǒng)的汽車油底盒都需要兩次以上的拉深成形，而本文對汽車油底盒進行了一次沖壓成形的可行性研究，得出以下結論：在零件成形過程中，合適的預脹壓力和預脹高度對零部件形成初始軟拉延筋及零件最終成形質量有很大的提高；合理的液室壓力加載曲線，得到的零件表面質量較好和壁厚分布均勻；合適的壓邊間隙可以獲得成形效果較好和壁厚分布均勻的零件；適當的增加凸模與板料的摩擦系數和選擇合適的凹模圓角半徑可以獲得成形質量較好的零件。 最后得到了合理的工藝路徑，由此獲得了合格的鋁合金異形底盒形件和汽車車油底盒。
[Abstract]:At present, more and more attention has been paid to energy saving and environmental pollution reduction in automobile lightweight, so aluminum alloy automotive parts are more and more widely used, but aluminum alloy sheet is much less formability than steel plate. The shape of automobile panel is complex, so it is easy to appear quality defects such as wrinkle and tensile crack by traditional cold stamping process. Sheet metal forming is a combination of traditional stamping process and hydroforming process. In the process of forming, the punch contact the sheet metal, and the pressure in the liquid chamber makes the sheet metal forming. Sheet metal hydro-forming has more advantages than traditional drawing technology, such as higher drawing ratio, better surface quality and higher dimensional accuracy. Pre-expansion is a kind of forming method in which the liquid chamber increases the pressure in advance and the sheet metal bulges in advance to form a soft drawing bar before the process of liquid filling deep drawing. The forming of soft drawing bars can increase the stability of sheet metal forming and obtain better parts quality. In this paper, taking the aluminum alloy special-shaped bottom box and the automobile oil bottom box as the research object, the forming process of their parts is analyzed, and the new technology of pre-expansion forming and liquid filling deep drawing is adopted to carry out the forming of the parts. The finite element simulation software Dynaform5.7.1 is used to simulate the aluminum alloy special-shaped bottom box and automobile oil bottom box. The forming results of aluminum alloy special-shaped bottom box and automobile oil bottom box were analyzed, and the influence of pre-expansion pressure, pre-expansion height, liquid chamber pressure and blank holder clearance on the forming of parts were summarized. Because the shape of automobile oil bottom box is complex and the distribution of stress and strain in sheet metal forming is very complicated, the traditional oil bottom box needs more than two drawing forming. In this paper, the feasibility of one stamping forming of automobile oil bottom box is studied. The following conclusions are drawn: in the forming process of the parts, the proper pre-expansion pressure and the pre-expansion height can greatly improve the initial soft drawing bars and the final forming quality of the parts, and the reasonable pressure loading curve of the liquid chamber, The good surface quality and uniform wall thickness distribution can be obtained, and the parts with good forming effect and uniform wall thickness distribution can be obtained with proper blank holder clearance. The parts with good forming quality can be obtained by increasing the friction coefficient between the punch and the sheet metal and selecting the proper radius of the corner of the die. Finally, the reasonable process path is obtained, and the qualified aluminum alloy special-shaped bottom box and automobile oil bottom box are obtained.
【學位授予單位】：哈爾濱理工大學
【學位級別】：碩士
【學位授予年份】：2015
【分類號】：TG389
本文編號：2284953
[Abstract]:At present, more and more attention has been paid to energy saving and environmental pollution reduction in automobile lightweight, so aluminum alloy automotive parts are more and more widely used, but aluminum alloy sheet is much less formability than steel plate. The shape of automobile panel is complex, so it is easy to appear quality defects such as wrinkle and tensile crack by traditional cold stamping process. Sheet metal forming is a combination of traditional stamping process and hydroforming process. In the process of forming, the punch contact the sheet metal, and the pressure in the liquid chamber makes the sheet metal forming. Sheet metal hydro-forming has more advantages than traditional drawing technology, such as higher drawing ratio, better surface quality and higher dimensional accuracy. Pre-expansion is a kind of forming method in which the liquid chamber increases the pressure in advance and the sheet metal bulges in advance to form a soft drawing bar before the process of liquid filling deep drawing. The forming of soft drawing bars can increase the stability of sheet metal forming and obtain better parts quality. In this paper, taking the aluminum alloy special-shaped bottom box and the automobile oil bottom box as the research object, the forming process of their parts is analyzed, and the new technology of pre-expansion forming and liquid filling deep drawing is adopted to carry out the forming of the parts. The finite element simulation software Dynaform5.7.1 is used to simulate the aluminum alloy special-shaped bottom box and automobile oil bottom box. The forming results of aluminum alloy special-shaped bottom box and automobile oil bottom box were analyzed, and the influence of pre-expansion pressure, pre-expansion height, liquid chamber pressure and blank holder clearance on the forming of parts were summarized. Because the shape of automobile oil bottom box is complex and the distribution of stress and strain in sheet metal forming is very complicated, the traditional oil bottom box needs more than two drawing forming. In this paper, the feasibility of one stamping forming of automobile oil bottom box is studied. The following conclusions are drawn: in the forming process of the parts, the proper pre-expansion pressure and the pre-expansion height can greatly improve the initial soft drawing bars and the final forming quality of the parts, and the reasonable pressure loading curve of the liquid chamber, The good surface quality and uniform wall thickness distribution can be obtained, and the parts with good forming effect and uniform wall thickness distribution can be obtained with proper blank holder clearance. The parts with good forming quality can be obtained by increasing the friction coefficient between the punch and the sheet metal and selecting the proper radius of the corner of the die. Finally, the reasonable process path is obtained, and the qualified aluminum alloy special-shaped bottom box and automobile oil bottom box are obtained.
【學位授予單位】：哈爾濱理工大學
【學位級別】：碩士
【學位授予年份】：2015
【分類號】：TG389
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