5A06铝合金端板构件成形工艺优化

所研究的铝合金端板构件为端部异向翻折零件,成形过程中局部极易产生起皱和破裂等缺陷。针对端板构件成形过程中存在的起皱及成形精度差等问题,通过对模具结构进行优化设计,实现了单道次整体成形,提高了产品的整体性及成形质量;同时,通过有限元模拟分析,选取合理的坯料形状,解决了零件成形过程中的开裂问题,并进行了试验验证。结果表明:与无顶板的传统凸、凹模结构相比,采用带凹模顶板的优化结构时,端板构件过渡区域起皱现象得到有效缓解,最大增厚率减少至6.7%;采用过渡圆角为R50 mm的凸耳结构坯料时,端板构件过渡区域最大减薄率减少至12.11%。

Optimization on forming process of 5A06 aluminum alloy end-plate

The aluminum alloy end-plate researched was a kind of typical part accompanied by end flange folding in the reverse direction,and defects such as winkles and cracks were extremely prone to occur during the forming process.According to the problems of wrinkles and poor forming accuracy in the forming process of end-plate,the mold structure was optimized to realize single-pass forming and improve the integrity and forming quality of products.Meanwhile,the appropriate blank shape was selected by the finite element analysis,which could eliminate the cracking problem during the forming process of products,and it was verified by test.The results show that compared to the traditional punch and die structure without die roof,the wrinkling of transition area in end-plate is effectively relieved by the optimized structure with die roof,and the maximum thickening rate is reduced to 6.7%.And the maximum thinning rate of transition area in end-plate was controlled to be 12.11%by adopting the blank with lug structure of R50 mm.