Wrinkling behavior of magnesium alloy tube in warm hydroforming

In tube hydroforming with axial feeding, under the effect of coupled internal pressure and axial stress, wrinkles often occur and affect the forming results. Wrinkling behavior of an AZ31B magnesium alloy tube was experimentally investigated with different loading paths at different temperatures. Features of wrinkles, including shape, radius and width, were acquired from the experiments, as well as the thickness distribution. Numerical simulations were carried out to reveal the stress state during warm hydroforming, and then the strain history of material at the top and bottom of the wrinkles were analyzed according to the stress tracks and yielding ellipse. Finally, effects of loading paths on expansion ratio limit of warm hydroforming were analyzed. It is verified that at a certain temperature, expansion ratio limit can be increased obviously by applying a proper loading path and realizing enough axial feeding.     

P91钢的形变强化行为

采用静力拉伸试验法研究了P91钢在566 ℃和室温时的形变强化与组织结构变化规律.结果表明,P91钢在室温条件下拉伸时自屈服至颈缩前的均匀塑性变形过程中的形变强化分3个阶段,颈缩至断裂前的局集塑性变形过程中的形变强化也分3个阶段.而在566 ℃时自屈服至颈缩前的均匀塑性变形过程中的形变强化为2个阶段.在局集塑性变形过程中,回火板条马氏体顺拉伸方向伸长变形的相对伸长量与颈缩量成双对数线性关系,马氏体板条束的位向朝拉伸方向转动的位向角与颈缩量也成双对数线性关系.塑性变形时位错组态出现胞状结构,随塑性变形量的增大,位错胞尺寸减小,并且顺拉伸方向伸长.形变强化能力决定了该钢在室温时的抗过载能力强.     

Combined tube and double sheet hydroforming for the manufacturing of complex parts

Modern lightweight construction, especially in the automotive industry, requires more and more complex components, which can be manufactured in one process step using the hydroforming technology. The combination of the tube and double sheet hydroforming is a new forming process, where a tube and two blanks are formed simultaneously in a die cavity, combining the advantages of both hydroforming variants. This paper deals with the fundamental considerations and investigations related to connection between tube and double sheet. The finite element analysis and laboratory trials were used in order to design the shape of the die cavity and to avoid wrinkles, material tearing and the collapse of the tube section during forming. The paper will also illustrate an analytical model for the prediction of the edge shape in the constrained bulging of a rectangular cup together with several technical solutions, which enabled a complete forming of the investigated part. Finally, the definition of a hydroforming material factor based on the analytical model of the hydraulic bulging process enables the right choice of sheets with different material strength and thickness for the hydroforming of hybrid components.     

镁合金管材的热态内压成形起皱行为分析

利用数值模拟和塑性理论分析AZ31B镁合金管材的热态内压成形过程的变形机理,找出临界起皱应力、应力状态及皱纹形状的变化规律。结果表明:随着温度升高,管材轴向抗起皱能力下降,其机理是材料的屈服强度和弹性模量随温度升高而下降;皱峰和皱谷处应力轨迹均在环向应变伸长和轴向应变压缩的区域;随着补料量的增大,皱峰处应力向壁厚减薄的方向发展,皱谷处应力向壁厚增加的方向发展;内压与材料屈服强度之比(相对压力)决定初始屈服时皱峰和皱谷处壁厚的变化情况,即温度较高时,相对压力较大,初始屈服时皱峰和皱谷处应力状态越易处于管壁呈减薄趋势的区域;当温度较低时,相对压力较小,初始屈服的皱峰和皱谷处的应力状态越易处于管壁有增厚趋势的区域;随着温度升高,相同加载路径下皱纹的高度和波长增大,皱纹趋向于向中间移动,且波数减少。     

Deformation characteristics during Y-shaped tube hydroforming of 6061 aluminum alloy

To manufacture lightweight tube components for aerospace oil circuit systems, an experiment was run to investigate the deformation characteristics on Y-shaped tube hydroforming of 6061 aluminum alloy. Both strain state and metallurgical structure indicate that there are four kinds of prevailing defects during Y-shaped tube hydroforming: bursting, lack of cylindricity, wrinkling, and thinning due to the poor plastic property of 6061 aluminum alloy. The danger of bursting prevails at the early stage of the operation as a result of excessively high internal pressure. In contrast, wrinkling prevails after the middle stage of the operation as a result of excessively axial feeding and cannot be eliminated during subsequent deformation. Lack of cylindricity is mainly because of insufficient axial feeding and internal pressure but can be eliminated by increasing internal pressure. Elongation and compression deformations are originated on protrusion and main pipe of Y-shape tube respectively all the way through the bulging process. Consequently, minimum and maximum thicknesses are at the top of protrusion and the bottom of Y-shape tube respectively, which induces a V-shape borderline of thickness distribution. According to the excessive plastic deformation, microstructure evolution is originated. Crystal grain of protrusion is elongated and its grain size is about 150 μm. In contrast, crystal grain of the middle zone of main tube is refined greatly, which grain size is 50 μm, decreased by 75%. These are useful to improve the component.     

管材内液塑性成形中的拉伸失稳分析

针对目前管材内液塑性成形中缺陷对工艺的影响,借助塑性力学分析手段,对轴向和环向的应力比对拉伸失稳极限应变的影响进行了分析。研究表明,胀形过程中,管坯的全部外载荷都是通过内部液压生成;内高压成形过程中,随应变比绝对值的增加,等效应变、环向应变及轴向应变呈指数增长趋势,而厚向应变对应力比的变化不敏感,其中集中性失稳应变量大约是分散性失稳的两倍,且随应变比绝对值的增加,集中性失稳的应变极限增加速度大于分散性失稳,破裂倾向降低明显。     

管材液压成形技术的发展——从前8届国际塑性加工会议看管材液压成形技术的发展

文章回顾了前8届国际塑性加工会议论文集中关于管材液压成形方面的文献,发现,早期的管材液压胀形技术内压较低,后来发展到可同时实现超高压和轴向补料;可成形零件的轴线由直线变为二维或三维空间曲线,种类大幅增加;适用于内高压成形的材料也由铝、铜、低碳钢等增加了不锈钢、铝合金、镁合金;同时热态内压成形技术也蓬勃发展起来。     

Investigation into the pre-forming's effect during multi-stages of tube hydroforming of aluminum alloy tube by using useful wrinkles

Tube hydroforming is a process for manufacturing of lightweight components, especially automotive parts, with advantages of cost and weight reduction, better structural integrity and increased strength and stiffness over the conventional stamping process. Generally, the hydroformed parts can be obtained by multi-stages made up of bending, pre-forming and finishing. Based on the characters of FEM and using the useful wrinkles, the process of multi-stages was investigated by using an aluminum alloy. For avoiding the typical failure modes such as folding back, wrinkling, buckling and fracture due to unreasonable selection of the internal pressure and the axial punch feeding, the optimization strategy was created and the process parameters were optimized by using “useful” wrinkles instead of “harmful” wrinkles in the pre-forming stage and in the finishing stage. The suitable pre-forming die cavity shape was discussed. The results from simulation keep a reasonable agreement with that from experiment.     

非比例加载路径下TRIP钢的应变硬化行为

通过大试样拉伸与小试样拉伸相结合的方法,分析冷轧TRIP780钢的瞬时应变硬化速率随应变水平的变化规律,详细讨论不同应变路径下TRIP钢应力应变曲线体现出的硬化特性,并对微观组织的演变进行扫描电镜观察。结果表明,TRIP钢不仅具有较高的初始硬化能力,而且具有较长应变范围内的后续硬化能力;非比例加载路径下TRIP钢应力应变曲线表现出了软化效应、瞬时硬化能力和相交效应;加载路径的改变,可引起位错的运动方向和稳定性发生改变,从而影响硬化行为。     

Optimization of loading conditions for tube hydroforming

Tube hydroforming is a developing technology with advanced features of lightness and unified part. This study investigates the best possible regulation for loading conditions between the internal pressure and the axial feeding by hydroforming of a T-shape metal tube. Using conjugate gradient method with finite element method, a program module is generated to check the hydroformed tube quality about its thickness uniformity and the geometry accuracy. Thereby, a batch mode and a sequential mode to optimize the loading conditions of the tube hydroforming process are created and investigated. Regarding the tube quality from the simulation results, the hydroforming process, which follows the loading curve generated by the sequential mode, is better than by the batch mode. The optimal loading procedure generated by this article can offer another possibility for engineer by determining the internal pressure and the axial feeding in tube hydroforming.     

管材液压胀形的FLSD研究

借助于PAMSTAMP对管材液压胀形(THF)过程进行了数值模拟,预测了基于应力的成形极限图(FLSD).发现并讨论了FLSD与传统成形极限图FLD之间存在的差别,分析了应变硬化指数n和壁厚t值对FLSD的影响.结果表明随着n值的增加,成形极限值越来越高;当壁厚值较小时,成形极限值降低.     

Y型三通管热态内高压成形多目标参数优化

基于Dynaform软件平台,建立Y型三通管热态内高压成形的三维弹塑性有限元模型.以左右冲头进给量、中间冲头后退量和内压力为因子,设计了正交试验方案,运用数值模拟分析方法,得到了三通管在不同加载路径下的支管高度和最小壁厚两个目标参数.探讨了各因素影响指标的主次顺序,采用综合平衡方法,获得了优化的加载路径.结果表明:通过优化的工艺方案可以得到综合质量较高的的Y型三通管.     

管材内高压成形新加载方式的研究

介绍了管材内高压成形过程中,一种新的内压加载方式--脉冲型加载方式.并通过建立相应的有限元模型,进行了内压脉冲型加载方式下管材内高压成形过程的模拟.通过对不同加载方式模拟结果的比较,分析了脉冲型加载方式对内高压成形中金属流动、变形区变形分布及局部过度减薄等方面产生的影响.模拟结果表明:脉冲型加载在管材内高压成形过程中可以使变形区的变形更加均匀,有利于抑制局部过度减薄、对抑制最后贴膜成形的圆角部位的过度减薄作用明显;脉冲型加载方式使变形更均匀的原因是减小了金属流动阻力,使金属流动更容易.     

Strain hardening and heterogeneous deformation during twinning in Hadfield steel

We identify the role of deformation twinning and twin–twin intersections on the strain hardening behavior of Hadfield steel single crystals using strain field measurements. In situ and ex situ strain field measurements resolved at micrometer length scales are obtained using digital image correlation. Ex situ measurements reveal that macroscopic twin-bands, which are composed of a mixture of fine twin-lamella and matrix material, generate approximately 30% axial strain. This measurement is comparable to strain predictions based on twinning crystallography. In situ measurements reveal that primary and secondary twins may nucleate simultaneously, but the primary twin-system remains predominantly active with increased deformation. The intersection of primary and secondary twin-systems was directly linked to an increase in the strain hardening response.     

内高压成形技术研究与应用新进展

介绍近年来在内高压成形机理、工艺、设备和应用方面的最新进展。针对大截面差管件,弯曲轴线异型截面构件和枝杈管3类工艺,给出典型零件缺陷形式、形状精度、壁厚分布和工艺参数的影响。详细介绍了皱纹控制与利用,降低整形压力的方法和内压与轴向力耦合作用下管材的塑性失稳起皱分析。最后给出了研制的典型内高压成形件及在汽车、航天、航空中的应用。     

圆管受轴压和充液内高压成形极限的理论解析

对管材的内高压成形过程进行理论解析,研究变形过程中材料的应力应变状态,从本质上揭示内高压成形工艺变形过程中的力学规律.研究了管材内高压成形提高成形极限的机理,给出了内高压成形时各应力状态在屈服椭圆上的分布,得出了管坯发生塑性变形时内压与轴向力之间的相互关系.最后,讨论了管材内高压成形过程中材料的变形路径在成形极限图上的范围和控制载荷匹配的基本原则.     

主要工艺参数对T型管液压成形性能的影响研究

为研究主要工艺参数对T型管液压成形性能的影响,文章提出一项综合评价指标,以评定T型管的成形质量.并采用正交试验设计与有限元仿真分析相结合的方法,研究模具过渡圆角半径、内压力加载路径和支管平衡冲头平衡力等主要工艺参数对T型管液压成形性能的影响,进而通过对试验结果的分析比较,找出最佳成形工艺方案.采用该方案进行实际加工试验,获得成形良好的T型管产品,且试验结果与数值模拟结果基本吻合,说明所用评价指标和试验设计方法在实际生产中有一定的参考价值.     

管材数控弯曲中的起皱分析与控制

针对内高压成形过程中,对弯曲件质量的严格要求,研究了低碳钢管材的数控弯管过程。采用数值模拟和实验,分析了不同弯曲半径、芯棒和管坯的间隙、芯棒位置和有无防皱块等参数对起皱的影响。结果表明,随着弯曲半径、芯棒直径、芯棒伸出量的增大及采用防皱块的情况下,管材弯曲起皱的趋势减小;在数值模拟的基础上进行了试验研究,试验结果和数值模拟结果吻合较好。采用二倍管径的弯曲半径,芯棒和管材间隙0.015D的情况下,能够有效地避免了弯曲内侧的起皱和外侧的减薄,成形出合格的副车架弯曲件,满足后续的内高压成形。     

管件液压成形加载路径的多目标优化

在管件液压成形过程中,加载路径对成形过程的影响最为重要。文章给出了一种新的加载路径优化方法,即精英保留非劣排序遗传算法(NSGA-Ⅱ)与成形数值模拟软件集成,实现对加载路径的自动寻优。该方法通过优化算法程序修改加载路径,自动调用数值模拟软件进行分析,在更大的解空间内自动寻找最优方案。文中以某汽车仪表板梁为例,采用该方法对液压成形中的加载路径进行优化分析。结果表明,通过该方法所获取的加载路径较通过人工寻优所获取的加载路径更趋于最优。另外,该方法一次运算能够同时获取多个Pareto最优解,可为加载路径的制订和设计人员的决策,提供更多的选择。