本文選題：汽車橋殼　切入點(diǎn)：預(yù)成形管坯　出處：《燕山大學(xué)》2016年碩士論文　論文類型：學(xué)位論文

【摘要】：脹壓成形工藝是一種新的橋殼制造方法,首先將初始管坯兩端縮徑和中部脹形得到一定形狀的預(yù)成形管坯,再經(jīng)充液壓制成形為帶有附加前蓋的橋殼管件。脹壓成形橋殼具有無(wú)焊縫、質(zhì)量輕、強(qiáng)度剛度好等優(yōu)點(diǎn),目前工藝中附加前蓋為球冠狀,材料利用率不夠高,工序較多,制造成本較高,本文設(shè)計(jì)了前平后球狀橋殼管件,并對(duì)充液壓制成形進(jìn)行了研究,以期提高材料利用率,減少工序,降低制造成本。對(duì)于前平后球狀橋殼,分析了預(yù)成形管坯充液壓制的典型橫截面、縱截面的變形過程,揭示了金屬的流動(dòng)規(guī)律,指出了壓制過程中可能存在前平面凹陷和后蓋開裂的問題及其影響因素。針對(duì)某載重5t的脹壓橋殼,設(shè)計(jì)了預(yù)成形管坯的形狀,給出了橋包部分后蓋半徑R1與制件橋包后蓋半徑R0的關(guān)系,即R_1=K_1R_0,給出了前蓋半徑R_2與后蓋半徑R_1的關(guān)系,即R_2=K_2R_1,其中K_1和K_2分別定義為后蓋系數(shù)和前蓋系數(shù)。設(shè)計(jì)了不同K_1和K_2的預(yù)成形管坯,進(jìn)行液壓脹形數(shù)值模擬,基于成形時(shí)管坯是否開裂和是否褶皺,初步確定了后蓋系數(shù)和前蓋系數(shù)的取值范圍。再對(duì)此范圍內(nèi)的預(yù)成形管坯進(jìn)行充液壓制模擬,根據(jù)成形時(shí)后蓋是否開裂和前平面是否凹陷,進(jìn)一步確定了后蓋系數(shù)和前蓋系數(shù)的合適取值范圍�；谝粋�(gè)最優(yōu)的預(yù)成形管坯形狀,先制定出某載重5t前平后球狀橋殼的脹壓成形工藝流程,并對(duì)初始管坯進(jìn)行縮徑、液壓脹形和充液壓制的數(shù)值模擬,得出橋殼壁厚分布規(guī)律。通過建立以橋殼成形性、工序數(shù)、生產(chǎn)成本和性能為評(píng)價(jià)指標(biāo)的評(píng)價(jià)模型,采用評(píng)分法對(duì)前后球狀脹壓成形橋殼和前平后球狀脹壓成形橋殼的兩種工藝方案進(jìn)行了初步評(píng)價(jià)。
[Abstract]:The bulging forming process is a new method for manufacturing the bridge shell. Firstly, the pre-formed tube billet with certain shape is obtained by reducing the diameters at both ends and forming the middle part of the initial tube billet. The bridge shell has the advantages of no weld seam, light weight, good strength and rigidity, etc. At present, the additional front cover is spherical shaped, the material utilization ratio is not high enough, and there are many working procedures. The manufacturing cost is high. In this paper, the pipe fittings of the front and back spherical bridge shell are designed, and the hydraulic shaping is studied in order to improve the material utilization ratio, reduce the working procedure and reduce the manufacturing cost. The deformation process of typical cross section and longitudinal section of pre-formed tube billet is analyzed, and the flow rule of metal is revealed. This paper points out the problems and influencing factors of front plane depression and back cover cracking in the process of pressing. The shape of preformed tube billet is designed for a 5 t bulging bridge shell with a load of 5 tons. The relation between the radius R1 of the back cover of the part of the bridge package and the radius R 0 of the back cover of the part of the bridge package is given, that is, the relation between the radius of the front cover and the radius of the back cover, R1, is given, that is, R1C / K1R0, the relation between the radius of the front cover and the radius of the rear cover, That is to say, R2K2R / S / 1, in which Kal _ 1 and K _ S _ 2 are defined as the back cover coefficient and the front cover coefficient, respectively. The pre-formed tube billets with different K _ S _ 1 and K _ 2 are designed for numerical simulation of hydraulic bulging, based on whether or not the tube billet is cracked and folded at the time of forming, The value range of the back cover coefficient and the front cover coefficient is preliminarily determined. The pre-formed tube billet in this range is then simulated by hydraulic filling, according to whether the back cover is cracked or not and whether the front plane is depressed or not. Based on an optimal shape of preformed tube billet, the expansion and compression forming process of a 5 t front and back spherical bridge shell with a load of 5 tons is first worked out, and the initial pipe blank is reduced in diameter, and the optimum value range of the back cover coefficient and the front cover coefficient is determined. Through the numerical simulation of hydraulic bulging and hydraulic filling, the distribution law of the wall thickness of the bridge shell is obtained. The evaluation model, which takes the formability of the bridge shell, the number of working procedures, the production cost and the performance of the bridge shell as the evaluation index, is established. In this paper, two kinds of technology schemes of bulbous bulge forming bridge shell and front and rear spherical expansion pressure forming bridge shell are preliminarily evaluated by using the scoring method.
【學(xué)位授予單位】：燕山大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2016
【分類號(hào)】：U466

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