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为提升5A02铝合金小弯曲半径薄壁管的弯曲成形极限,针对Φ30 mm×1.0 mm、弯曲半径为0.8D的管坯,开展了推-旋一体弯曲成形关键参数影响研究。结合Abaqus有限元模拟与工艺实验,系统探究了管坯进给速度V1、旋轮转速V2、反推压强P及其加载路径对成形质量的影响。结果表明:降低管坯进给速度V1可有效抑制内侧起皱,当V1由15 mm·s-1减小至3 mm·s-1,内侧增厚率降低了5.1%。旋轮转速V2对改善成形质量具有关键作用,与旋轮固定形式相比,当旋轮转速增大至V2=1.5V1时,内侧增厚率降低了8.0%、输出端伸长量延长了107.8%,但继续增大V2,其改善效果趋于饱和。反推压强P需精确控制,P小于70 MPa易导致不贴模与起皱,大于70 MPa则会加剧壁厚不均并抑制材料伸长。据此确定了较优工艺窗口:在70 MPa的反推压强P下,结合D加载路径(P经线性变化在3/4管坯行程时达到最大值),可获得无缺陷、质量良好的弯管。
Abstract：To enhance the bending forming limit of 5A02 aluminum alloy thin-walled tubes with small bending radius, the influence of key parameters in push-spin integrated bending forming for Φ30 mm×1. 0 mm tube blanks with a bending radius of 0. 8D was investigated.Combining Abaqus finite element simulation with process experiments, the influence of tube blank feed rate V1, spin wheel speed V2,back pressure P and its loading path on forming quality were systematically investigated. The results indicate that reducing the tube blank feed rate V1 can effectively suppress inner wrinkling, when V1 decreases from 15 mm·s-1 to 3 mm·s-1, the inner wall thickening rate decreases by 5. 1%. Spin wheel speed V2 plays a crucial role in improving forming quality, compared to a fixed spinneret configuration,increasing V2 to 1. 5V1 reduces inner wall thickening rate by 8. 0% and extends the stick-out length by 107. 8%, however, further increases of V2 shows diminishing returns. The back pressure P requires precise control, the value below 70 MPa may cause non-adherence to the die and wrinkling, while values above 70 MPa exacerbate wall thickness non-uniformity and inhibit material elongation; based on this,an optimal process window is determined: under the back pressure P of 70 MPa, combined with the D loading path(where P undergoes linear change and reaches the maximum value at 3/4 of the tube blank stroke), high-quality bent tubes without defects can be produced.
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基本信息:
中图分类号:TG306
引用信息:
[1]刘杰,范玉斌,徐雪峰,等.0.8D弯曲半径铝合金薄壁管推-旋一体弯曲成形关键参数影响研究[J].塑性工程学报().
基金信息:
江西省自然科学基金资助项目(20224BAB214050); 国家自然科学基金资助项目(52365050; 52265052); 江西省重点研发计划项目(20243BBG71002)
2025-12-31
2025-12-31
2025-12-31