| 457 | 7 | 169 |
| 下载次数 | 被引频次 | 阅读次数 |
为精确控制铝合金大型薄壁构件电磁渐进成形质量，基于LS-DYNA EM平台建立了铝合金大型薄壁构件双线圈电磁渐进成形三维有限元模型，通过数值模拟研究了双线圈放电时板料的动态变形行为，并探究了自由拉胀成形阶段放电电压、放电间隙、放电路径和偏转角度对成形质量的影响规律。结果表明：应力波由两线圈作用区域开始以近圆的形式向外传播，在板料中心处汇聚后沿双线圈中心连线垂直方向继续传播，直至动能耗尽；从双线圈作用区域到板料中心，等效应变逐渐增大，随着应力波不断传播，传播路径上单元的应变速率逐渐减小。采用小间隙、“低+高”的放电电压组合及较低的线圈偏转角度有利于提高成形深度及成形均匀性；相较于顺序放电，间隔放电可以提高成形深度，但成形均匀性稍有降低。通过得到的8道次间隔放电方案能获得最大的成形深度和最佳成形均匀性，最大平均成形深度达到47.4 mm,最小成形深度标准差约为4.01。
Abstract：To accurately control the electromagnetic incremental forming(EMIF) quality of aluminum alloy large thin-walled components, the three-dimensional finite element model of dual-coil EMIF of aluminum alloy large thin-walled components was established based on LS-DYNA EM platform. The dynamic deformation behavior of sheet metal under dual-coil discharge was studied by numerical simulation, and the influence of discharge voltage, discharge gap, discharge path and rotation angle on the forming quality was investigated in the free drawing and bulging forming stage. The results show that the stress wave starts from the action area of the dual-coil and propagates outward in a nearly circular form, and then continues to propagate along the direction perpendicular to the connecting line of the dual-coil centers after converging at the center of the sheet, until the kinetic energy is exhausted. From the action area of the dual-coil to the center of the sheet, the effective strain increases gradually, and the strain rate of the element along the propagation path decreases gradually with the continuous propagation of stress wave. The combination of small gap, “low+high” discharge voltage and low coil rotation angle is helpful to improve the forming depth and forming uniformity. Compared with the sequential discharge, the interval discharge can improve the forming depth, but the forming uniformity is slightly reduced. Using the eight-pass interval discharge scheme, the maximum forming depth and the best forming uniformity are obtained, with the maximum average depth of 47.4 mm and the minimum standard deviation of forming depth of about 4.01.
[1] SU H L,HUANG L,LI J J,et al.Inhomogeneous deformation behaviors of oblique hole-flanging parts during electromagnetic forming[J].Journal of Manufacturing Processes,2020,52:1-11.
[2] LUO W Y,HUANG L,LI J J,et al.A novel multi-layer coil for a large and thick-walled component by electromagnetic forming[J].Journal of Materials Processing Technology,2014,214(11):2811-2819.
[3] LI C F,LIU D H,YU H P,et al.Research on formability of 5052 aluminum alloy sheet in a quasi-static-dynamic tensile process[J].International Journal of Machine Tools & Manufacture,2009,49(2):117-124.
[4] 李宝蓉，张丽娜.H-2B运载火箭贮箱制造技术与应用[J].航天制造技术，2008,(5):39-41.LI Baorong,ZHANG Lina.Manufacturing technology and application of H-2B launch vehicle tanks[J].Aerospace Manufacturing Technology,2008,(5):39-41.
[5] 姚君山，蔡益飞，李程刚.运载火箭箭体结构制造技术发展与应用[J].航空制造技术，2007,(10):36-42.YAO Junshan,CAI Yifei,LI Chenggang.Launch vehicle structure manufacturing technology development and application[J].Aerospace Manufacturing Technology,2007,(10):36-42.
[6] 苑世剑，刘伟，徐永超.板材液压成形技术与装备新进展[J].机械工程学报，2015,51(8):20-28.YUAN Shijian,LIU Wei,XU Yongchao.New development on technology and equipment of sheet hydroforming[J].Journal of Mechanical Engineering,2015,51(8):20-28.
[7] ZHU H,HUANG L,LI J J,et al.Strengthening mechanism in laser-welded 2219 aluminium alloy under the cooperative effects of aging treatment and pulsed electromagnetic loadings[J].Materials Science and Engineering A,2017,714:124-139.
[8] 汪志强，黄亮，李建军，等.大型铝合金曲面零件电磁渐进成形线圈结构优化设计[J].塑性工程学报，2015,22(6):71-77.WANG Zhiqiang,HUANG Liang,LI Jianjun,et al.Structure optimization design of coil on electromagnetic incremental forming of large aluminum alloy curved surface parts[J].Journal of Plasticity Engineering,2015,22(6):71-77.
[9] CUI X H,MO J H,LI J J,et al.Electromagnetic incremental forming (EMIF):A novel aluminum alloy sheet and tube forming technology[J].Journal of Materials Processing Technology,2014,214(2):409-427.
[10] 严思梁.基于建模的铝合金薄壁件电磁渐进成形机理研究[D].西安：西北工业大学，2017.YAN Siliang.Modelling based study on mechanism of electromagnetic incremental forming of thin-walled aluminum component[D].Xi′an:Northwestern Polytechnical University,2017.
[11] SU H L,HUANG L,LI J J,et al.On the forming uniformity during a single layer forming of electromagnetic incremental forming[J].The International Journal of Advanced Manufacturing Technology,2020,107(11):4561-4572.
[12] LI H W,YAO X,YAN S L,et al.Analysis of forming defects in electromagnetic incremental forming of a large-size thin-walled ellipsoid surface part of aluminum alloy[J].Journal of Materials Processing Technology,2018,255:703-715.
[13] LIU X L,HUANG L,LI J J,et al.An electromagnetic incremental forming (EMIF) strategy for large-scale parts of aluminum alloy based on dual coil[J].International Journal of Advanced Manufacturing Technology,2019,104(5):1-21.
[14] 黄尚宇，常志华，王立峰，等.板坯电磁成形载荷计算方法及分布特性[J].中国有色金属学报，1998,8(3):76-81.HUANG Shangyu,CHANG Zhihua,WANG Lifeng,et al.Calculation and distribution of forming load for sheet metal magnetic forming[J].The Chinese Journal of Nonferrous Metals,1998(3):76-81.
[15] DANNEMANN K A,CHALIVENDRA V B,SONG B.Dynamic behavior of materials[J].Experimental Mechanics,2012,52(2):117-118.
[16] ZHANG Q X,HUANG L,LI J J,et al.Investigation of dynamic deformation behaviour of large-size sheet metal parts under local Lorentz force[J].Journal of Materials Processing Technology,2018,265:20-33.
[17]CUI X H,LI J J,MO J H,et al.Investigation of large sheet deformation process in electromagnetic incremental forming[J].Materials&Design,2015,76:86-96.
基本信息:
中图分类号:TG391
引用信息:
[1]薛克敏,刘超,李萍,等.铝合金大型薄壁构件电磁渐进成形数值模拟[J].塑性工程学报,2022,29(06):41-50.
基金信息:
国家自然科学基金青年基金资助项目(51705119); 陕西省高性能精确成形技术与装备重点实验室开放基金基金资助项目(PFTE-2020-KF-01); 材料成形与模具技术国家重点实验室开放基金基金资助项目(P2021-015)
2022-07-01
2022-07-01
2022-07-01