Al6063管件外增量成形工艺研究

目的 研究6063铝合金管件外增量成形过程，分析管件的成形效果，改进管件成形质量。方法 设置3组目标成形管件，使用Abaqus软件进行成形过程的数值模拟，通过考察成形管件的几何精度、壁厚分布、表面质量、成形力，分析成形质量和可能出现的问题。通过使用长120 mm、直径50 mm、壁厚1.5 mm的Al6063铝管进行管件外增量成形实验，验证数值模拟结果的可靠性。结果 成形管件会发生管端变形现象，具体表现为管端不圆与轴向伸长，成形件管端椭圆度为10.11%，管端变形程度与成形道次成正比，且在距离管端越近的成形区域，管端变形越明显。管壁成形区厚度增大并呈现不均匀分布。成形件管壁直线度偏差为0.34，且表面质量与径向进给量和轴向进给速度成反比，管件的圆角尺寸难以严格控制。径向力是成形过程中主要的成形力，其大小与工具头直径成正比。结论 管件外增量成形原理可靠，基于此能够实现多种目标管件的成形。由于成形原理的限制，成形件的成形质量还有很大的提升空间，合理制定工艺参数对提高成形质量十分重要。

External Incremental Forming Process of Al6063 Pipe Fitting

The work aims to explore the external incremental forming process for 6063 aluminum alloy pipe fittings, analyze the forming effects, and enhance the quality of the formed pipe fittings. Three sets of target fittings were selected, and numerical simulations of the forming process were conducted with Abaqus software. The geometric accuracy, surface quality, and forming forces of the formed pipe fittings were analyzed. Experimental research on incremental forming was carried out with AL6063 aluminum alloy pipe fittings with dimensions of 120 mm in length, 50 mm in diameter, and 1.5 mm in wall thickness. The simulation results were validated by physical experiments. The findings indicated that deformation occurred at the end of the formed pipe fittings, resulting in non-roundness and axial elongation. The pipe end ovality of the formed pipe fittings was 10.11%. The extent of the end deformation increased proportionally with the number of forming passes, and the deformation was more pronounced as the forming region approached the end of the fittings. The wall thickness in the forming region exhibited uneven distribution with an overall increase. The pipe wall straightness deviation of the formed pipe fittings was 0.34, and the surface quality was inversely proportional to the radial feed rate and axial feed velocity. It was difficult to control the fillet size of pipe fittings accurately. The main forming force during the process was the radial force, which was directly related to the tool head diameter. In conclusion, the principle of external incremental forming for pipe fittings is reliable and can achieve the forming of various types of pipe fittings. Due to the limitations of the forming principle, there is still a lot of room for improvement in the forming quality of the parts. It is crucial to develop reasonable process parameters in order to improve the forming quality.