旋轮参数对铝合金分形旋压的影响规律

铝合金分形旋压是一个复杂的多因素耦合影响的塑性成形过程,研究其旋轮参数对成形过程的影响可为相关成形参数的确定和优化设计提供理论依据。基于建立的可靠的铝合金分形旋压三维有限元模型,文章研究揭示了旋轮分形角、旋轮圆角半径、旋轮轴向进给比等旋轮参数对成形过程中的切向拉应力、周向压应力以及成形凸缘的不均匀变形程度和最终壁厚偏差的影响规律。结果表明,增大旋轮分形角,可以消除旋轮前方的金属堆积和降低成形过程中坯料开裂失效的可能性,可以使得成形凸缘的不均匀变形程度减小和成形精度降低;旋轮圆角半径的改变,对消除旋轮前方的金属堆积和降低成形过程中坯料开裂失效的可能性影响并不明显,但增大旋轮圆角半径,可以使得成形凸缘的不均匀变形程度增大和成形精度升高;旋轮轴向进给比的改变,对消除旋轮前方的金属堆积和成形凸缘的成形精度的影响并不明显,但增大旋轮轴向进给比,可以降低成形过程中坯料开裂失效的可能性,可以使得成形凸缘的不均匀变形程度减小。

Research on influences of roller parameters on splitting spinning of aluminum alloy

Splitting spinning of aluminum alloy is a much complex plastic process with multi-factors coupling interactive effects.The analysis of influences of roller parameters on the forming process may provide an important guide for determining the forming parameters and the optimum design of splitting spinning of aluminum alloy.Based on the established reliable 3D-FE model of splitting spinning of aluminum alloy,the influences of roller parameters,including splitting angle,radius of corner and feed ratio of roller,on the variations of the tangential stress,circumferential stress and inhomogeneous deformation and final thickness deviation of deformed flanges have been revealed.The results shows that:the increase of splitting angle of roller may eliminate the metal accumulation in front of roller,decrease the possibility of material failure and reduce inhomogeneous deformation and forming precision;the influences of radius of corner of roller on the metal accumulation in front of roller and the possibility of material failure are not obvious,and the increase of radius of corner of roller may increase inhomogeneous deformation and forming precision;and the influences of feed ratio of roller on the metal accumulation in front of roller and forming precision are not obvious,and the increase of feed ratio of roller may decrease the possibility of material failure and reduce inhomogeneous deformation.