锻压技术

带侧枝复杂铝合金构件包络成形工艺分析与金属流线模拟

英文标题：Enveloping forming process analysis and metal streamlines simulation on aluminum alloy complex components with lateral branch

作者：冯玮1 2 3 金晁翼1 邓加东3

单位：1. 武汉理工大学 2. 湖北省材料绿色精密成形工程技术研究中心 3. 现代汽车零部件技术湖北省重点实验室

关键词：铝合金带侧枝复杂构件包络成形成形载荷金属流线

分类号：TG312

出版年,卷(期):页码：2022,47(4):141-149

摘要：

针对带侧枝复杂铝合金构件的几何特点，提出采用包络成形工艺成形该零件，并利用DEFORM-3D软件模拟了其成形过程，分析了等效应变和成形载荷变化特点，并通过DEFORM-3D软件的Flownet功能模拟了该构件包络成形过程中金属流线分布和演变特点，最后通过工艺实验进行了验证。结果表明：带侧枝复杂铝合金构件包络成形过程中，构件上的凸台、侧枝、飞边等结构在包络模和凹模的作用下逐渐成形，构件右侧半圆锥形部分为大变形区，左侧圆柱形部分为小变形区；构件成形载荷在包络成形阶段随着成形时间的增加呈周期性波动，在包络模保压整形阶段，成形载荷随着保压时间的增大，先逐渐减小，然后呈稳定的周期性波动；构件中间区域和右侧半圆锥形区域的金属流线变化较大，凸台处的金属流线存在穿流、涡流和回流现象。通过比较，该构件包络成形的模拟结果与实验结果一致。

For geometric characteristics of aluminum alloy complex components with lateral branch, the enveloping forming process was proposed to form the components, and its forming process was simulated by software DEFORM-3D. Then, the change characteristics of effective strain and forming load were analyzed, and the distribution and evolution characteristics of metal streamlines were simulated in the enveloping forming process of the components by the Flownet function of software DEFORM-3D. Finally, the experiment was carried out to verify the simulation results. The results show that in the enveloping forming process of the aluminum alloy complex components with lateral branch, the structures such as bosses, lateral branches and flashes on the components are gradually formed by the action of enveloping die and concave die. The semi-conical part on the right side of the component is a large deformation area, and the cylindrical part on the left side is a small deformation area. The forming load of the component fluctuates periodically with the increasing of forming time in the enveloping forming stage, and the forming load decreases gradually with the increasing of holding time and then presents a stable periodic fluctuation in the enveloping die holding and shaping stage. The metal streamlines in the middle area and the semi-conical area on the right side of the component vary greatly, and the metal streamlines appear through-flow, eddy-flow and backflow phenomenon at the boss. By comparison, the simulation results are in good agreement with the experimental results.

基金项目：

国家自然科学基金资助项目(51805391);高等学校学科创新引智计划资助项目（B17034）；教育部创新团队发展计划项目(IRT_17R83)

作者简介：冯玮（1973-），女，博士，副教授，硕士生导师 E-mail：fw7757@sina.com

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