镁合金笔记本电脑外壳的温成形技术研究

采用0.6mm厚的AZ31镁合金材料,以温成形方式获得了复杂外形尺寸的笔记本电脑外壳.通过研究温度对AZ31镁合金板料拉深成形性能的影响发现:180～280℃成形的镁合金电脑外壳零件不会出现断裂和起皱缺陷,但角部高度随成形温度的升高而增加;低于180℃成形,零件圆角出现褶皱;高于280℃成形,圆角被拉裂;并且成形速度和摩擦也会影响零件成形.     

Investigation on the effect of friction stir processing on the superplastic forming of AZ31B alloy

Superplastic forming has now become conventional for forming complex parts from sheet metals. In many superplastically formed aerospace components, only a selective region undergoes superplastic forming. In those cases, instead of selecting a material exhibiting superplastic properties, a light weight and low cost material can be chosen and its microstructure can be modified locally by the Friction Stir Processing (FSP) technique. In this work, AZ31B magnesium alloy is chosen, and friction stir processing is performed by varying the process parameters, such as tool axial force, tool traversing speed and tool rotational speed. The process parameter that produced equiaxed grains in the stirred zone with a grain size less than 10 μm is selected. With this parameter, single pass FSP, multiple pass FSP without overlapping and multiple pass FSP with overlapping are performed on the AZ31B magnesium alloy sheets and their superplastic behaviour was examined. Also the theoretical modelling was carried out to determine the strain rate sensitivity for the friction stir processed AZ31B magnesium alloy and for the nonprocessed AZ31B magnesium alloy. It is found that the strain rate sensitivity for the friction stir processed component has increased, when compared to the base metal.     

镁合金板材成形极限图(FLD)的实验研究

首次利用电蚀网格法,在BCS-30D板材成形性试验机上进行镁合金板材成形实验,利用先进的ASAME自动应变测量系统进行应变测量分析,测试镁合金板材的成形极限图(FLD).实验表明,室温下AZ31B镁合金冷轧态板材的力学性能和冲压性能不佳,难以完成成形极限图的测试,不具备成形加工能力;热轧态镁合金板材具有一定的塑性和成形性能,并测试了其成形极限图.成形极限曲线FLC的测试对制订镁合金板材的冲压成形工艺提供了理论依据.     

加工方式对AZ31变形镁合金热拉伸流变应力的影响

针对不同方法制备的AZ31镁合金薄板,利用热拉伸试验机和金相显微镜对其在不同温度和变形速率下的流变应力进行了实验研究.结果表明:挤压、交叉、热轧和冷轧等方法制备的AZ31镁合金薄板的应力-应变曲线基本特征是相同的.峰值流变应力随变形温度的升高和应变速率的降低而降低,在低温时具有明显的厚度效应;当温度大于350℃时峰值流变应力几乎不随板材厚度变化而变化;应变速率小于1.0×10-2s-1,变形温度大于150℃下所有AZ31薄板的延伸率均δ≥45%;单向轧制薄板的各向异性随温度提高减小.     

AZ80镁合金板材快速气压胀形工艺研究

快速气压胀形是一种源自超塑性气压胀形的新成形技术,为获得AZ80镁合金板材的快速气压胀形成形性能,以挤压-冷轧加工的AZ80镁合金板材为研究对象,采用半球件自由胀形实验研究了1.0 mm厚板材在250~400℃和0.4~1.6 MPa下的快速气压胀形能力,分析了半球件和盒形件的壁厚分布规律,并对快速气压胀形过程的断裂模式进行了研究.研究结果表明,AZ80镁合金板材在350℃下具有良好的快速气压胀形能力,在350℃、0.8 MPa下的胀形高度可达38 mm,高径比达到0.95,并得到胀破高度、胀形高度与胀形时间之间的关系.在此基础上,进行了1.2 mm厚板材的盒形件快速气压胀形实验,得到高20 mm的轮廓清晰、表面质量良好的胀形件.     

不锈钢外板对 2219 铝合金拼焊板胀形性能的影响

目的现有2219铝合金板材宽度不能满足大型复杂曲面件整体流体高压成形需要,仍需采用焊接方法制备成形坯料,焊缝的存在导致铝合金拼焊板整体性能不均匀,影响成形性能及壁厚分布。方法提出2219铝合金拼焊板的双层板流体高压成形方法,采用1.8 mm厚铝合金拼焊板作为内层板,1mm厚不锈钢板作为外层板,进行双层板胀形实验研究。对比分析了单层板与双层板条件下2219铝合金拼焊板的成形极限、应变及壁厚分布。结果外层板的存在能够使板材的极限成形高度和极限应变增加,同时使壁厚分布更加均匀。结论双层板之间存在界面摩擦,可以提高内层拼焊板的成形极限、改善壁厚分布。     

镁合金塑性成形性能实验与数值模拟研究

对ME20M镁合金板料进行了热拉深成形性能实验与数值模拟.研究表明,ME20M镁板热拉深成形极限高度随实验参数的不同而不同,其塑性成形性能随温度的升高明显改善;数值模拟可以很好地预测不同实验参数下镁合金板料热拉深成形极限的高度.对热拉深成形件传力区部位进行金相实验得知,合理控制热拉深实验参数能保证镁合金塑性成形件微观组织,进而保证成形件质量.     

Improvement of ductility in magnesium alloy sheet using laser scanning treatment

This paper suggests a novel method for improving the ductility of magnesium alloy sheets using a laser scanning treatment combined with a defocusing technique. The crystallographic orientation on both surface regions of the AZ31B magnesium alloy sheet processed using this method was changed from a strong basal texture to an almost random texture. The laser-scanned magnesium alloy sheet showed enhanced tensile elongation of up to 50% with a similar a tensile strength.     

电磁成形技术在钛合金板材成形中的应用

钛合金是航空航天领域主要的轻质结构材料,强度高,但不易成形且回弹大,而电磁成形技术的发展为钛合金零件的精密高效成形提供了新的有效途径.从高速增塑、成形工艺、数值仿真3个方面综述了电磁成形技术在钛合金板材成形的应用研究情况,并结合笔者的研究经历对钛合金电磁成形中存在的问题进行了简要分析.在此基础上,着重综述了电磁成形技术...     

Microstructure and formability of AZ31B magnesium alloy sheet under continuous pulse current

Utilising electropulsing treatment (EPT) to improve the formability of metals is of paramount importance for engineering applications. The effects of EPT on the microstructure and formability of AZ31B magnesium alloy sheet were investigated. The results indicated that the microstructure and mechanical properties were slightly improved with the increase of current density, while the formability was promoted distinctly. Besides, the formability of the specimen after EPT was better than that of the specimen annealed at the same temperature, which indicated that pulse current can effectively increase the formability of the sheet. Further studies confirmed that the athermal effect caused by the pulse current made great contribution to the dislocation mobility and improved the formability of the sheet.     

Rotation friction pressing riveting of AZ31 magnesium alloy sheet

A kind of joining method for magnesium alloys, rotation friction pressing riveting (RFPR), is proposed in this paper. In RFPR operation, a rivet with a plug rotating at high speed is brought to contact with the riveted sheets, generating frictional heat between the rivet and riveted sheets, which softens the sheet materials and enables the rivet to be drilled into the sheets under reduced force. When fully inserted, the rivet is stopped rotating, and the plug is immediately pressed into the shank of the rivet by a punch. The expansive deformation of the rivet shank occurs under the action of the plug, thereby forming a mechanical interlock between the rivet and the sheets to fasten the sheets together. The studies show that RFPR of AZ31 magnesium alloy sheet can be carried out at ambient temperature, and provides the joints with superior shear strength and fatigue property when compared with self-piercing riveting (SPR). The effects of the operating parameters of RFPR process on the quality of the joints were investigated in the study. The results shows that while the rivet rotation speed little affects the shear strength of RFPR joints, the punch pressure has a significant influence on the mechanical properties of the RFPR joints. A numerical analysis was also performed to understand the effect of the punch pressure on the interlock between the rivet and the sheets, and the stress and strain distribution inside the sheet materials around the rivet. The results show that the interlock increased with the punch pressure and there is residual compressive stress inside the sheet materials, which seems to explain the good fatigue property of RFPR joints observed.     

Cryorolling and warm forming of AA6061 aluminum alloy sheets

Cryorolling is a severe plastic deformation (SPD) process used to obtain ultrafine-grained aluminum alloy sheets along with higher strength and hardness than in conventional cold rolling, but it results in poor formability. An alternative method to improve both strength and formability of cryorolled sheets by warm forming after cryorolling without any post-heat treatment is proposed in this work. The formability of cryorolled AA6061 Al alloy sheets in the warm working temperature range is characterized in terms of forming limit diagrams (FLDs) and limiting dome height (LDH). Strain distributions and thinning in biaxially stretched samples are studied. Hardness of the formed samples is correlated with ultimate tensile strength to estimate post-forming mechanical properties. The limit strains and LDH have been found to be higher than in the case of the conventional processing route (cold rolled, annealed and formed at room temperature), making this hybrid route capable of producing sheet metal parts of aluminum alloys with high strength and formability. In order to combine the advantages of enhanced formability and better post-forming strength than the conventional cold rolled and annealed sheets, warm forming at 250°C has been found to be suitable for this alloy in the temperature range that has been studied.     

Research on Thermal Deep-drawing Technology of Magnesium Alloy (AZ31B) Sheets

Forming technology of Mg alloy (AZ31B) sheets can be investigated by thermal deep drawing experiments. In the experiments, the blank holder and die contacting with the blank were heated to the same temperature as the blank by using the heating facility. The circular blank heated in an oven is formed at a temperature range of 100~400℃ to obtain the optimum forming temperature range and the effects of major technical parameters on the workpiece quality.It is found that the blank is brittle at temperatures lower than 200℃.Temperatures higher than 400℃ are not suitable for forming of the sheets because of severe oxidation and wrinkling.AZ31B shows an excellent formability at temperatures from 300 to 350℃ and can be formed into a workpiece with good quality. When the blank holder force is 9 kN, extruded sheets with a thickness of 1 mm can be formed into cups without wrinkling. Workpieces show strong anisotropic deformation behavior on the flanges.     

The modified temperature term on Johnson Cook model for AZ31 magnesium alloy

The quasi‐state and dynamic mechanism of AZ31 magnesium alloy at a strain rates range of 0.001 s^‐1–2500 s^‐1 under a temperature range of 20 °C–250 °C were researched by compression tests using the electronic universal testing machine and split Hopkinson pressure bar system. The true stress‐strain curves at different strain rates and evaluated temperatures were obtained. The result shows that the thermal soften effect of AZ31 magnesium alloy is significant. By modifying the temperature term of the original Johnson Cook model of AZ31 magnesium alloy, a modified Johnson Cook model of AZ31 magnesium alloy has been proposed to reveal thermal soften effect on the deformation behavior of AZ31 magnesium alloy more precisely. With the modified Johnson Cook model and fracture model, the finite element method simulation of AZ31 magnesium alloy hat shaped specimen under impacting was conducted. The numerical simulation result is consistent with the experimental result, which indicates that the modified Johnson Cook model and fracture model are greatly valid to predict the deformation and fracture behavior of the AZ31 magnesium alloy hat shaped specimen under impacting.     

Deformation characteristics of fine grained magnesium alloy AZ31B thin sheet during rapid gas blow forming

Abstract

Decreasing the forming time in gas blow forming using fine grained Mg alloy AZ31B thin sheet with a thickness of 0·6 mm was studied in this work. Tensile tests and gas blow forming using stepwise pressurisation profiles were performed to explore the deformation behaviour of a fine grained AZ31B Mg alloy sheet. The alloy sheets were successfully deformed into hemispherical domes using two proposed stepwise pressurisation profiles during gas blow forming. As a result, significant reduction in forming time was achieved. Maximum effective deformation rates of 1·02 × 10^–2 and 1·98 × 10^–2 s^–1 were obtained at 300 and 370°C respectively. It was feasible to form a hemispherical dome with a height of 20 mm in less than 80 s at 370°C. The results confirmed that the thickness distribution along the centreline of the formed dome was sensitive to the pressurisation profiles. A higher thinning effect was observed at 370°C due to the higher deformation rate imposed during forming. Grain growth was not a serious problem for forming even at 370°C, and static grain growth should be the major factor resulting in grain growth during forming.     

Prediction of flow curves and forming limit curves of Mg alloy thin sheets using ANN-based models

Multivariable empirical models based on artificial neural networks were developed in order to predict the flow curves and forming limit curves of AZ31 magnesium alloy thin sheets, in warm forming conditions, vs. process parameters and fibre orientation. Experimental tensile and hemispherical punch tests were carried out in order to obtain the experimental data set, in terms of flow curves and forming limit curves, to be used to train the artificial neural networks. A preliminary study, based on the leave one-out-cross validation methodology, has proven the very good predictive capability of the ANN-based models in modelling both flow curves (flow stress level, curve shape and strain at the onset of necking) and forming limit curves (curve shape, major strain values and minor strain limit) under different process conditions and fibre orientations. Then, the generalisation capability of the neural models in capturing the effect of process parameters and fibre orientation on flow curves and formability has been proven by the excellent agreement, in terms of the high correlation coefficients, low relative errors and average absolute relative errors, between predicted and experimental results not investigated in the training set.     

Isothermal Gas Forming of Mg Alloy AZ31 Sheet

There have been reports on sheet forming of Mg alloy in industry via the punch and die method;this paper is probably the first formal one for studying the sheet formability of AZ31 employing pressurized gas to press the sheet into a female die cavity at various elevated temperatures.The results indicate it is feasible to form a rectangular box via pressurized gas from extruded sheets of 0.5 and 1.7 mm thick.The formed box has 1:2 depth over width ratio,which should be large enough when dealing with realistic industrial sheet forming parts.Presently,forming a sheet of 0.5 mm thick is considered a technical challenge by industry,and it is conquered as demonstrated in this paper.Gas forming technique applied to Mg alloy is unprecedented and shows potential for industrial utilization.     

循环道次对高温叠轧AZ31镁合金板材组织与性能的影响

目的通过高温累积叠轧工艺制备出高强度的镁合金,并研究该过程中循环道次对AZ31镁合金板材的微观组织与性能的具体影响。方法对累积叠轧1～5次板材进行微观组织观察,并进行显微硬度的测试,得到不同板材的硬度值,通过X射线衍射分析得到不同板材的取向结果,最终进行力学性能实验,并对比分析。结果随着循环道次的增加,板材抗拉强度有明显改变。从260 MPa先增加至310 MPa,最后稳定在350 MPa左右;非基面织构比重增加;断裂伸长率先降低后升高并稳定在10%左右。结论累积叠轧工艺使得AZ31镁合金板材产生了加工硬化,并显著细化了晶粒。循环道次的增加、孪晶产生和晶界数量显著增多导致强度进一步提高。     

Drawability of AZ31 magnesium alloy sheet produced by equal channel angular rolling at room temperature

The objective of this study is to investigate the possibility of improved drawability of AZ31 magnesium alloy sheet produced by equal channel angular rolling process at room temperature. Although with similar optical microstructure, the limiting drawing ratio of AZ31 magnesium alloy sheet is improved from 1.2 to 1.6 for the specimens before and after equal channel angular rolling, which is due to the changing crystal orientation that induces shear deformation through this process. The enhanced drawability in AZ31 magnesium alloy sheet provides the possibility for drawing at ambient temperature by controlling the crystal orientation in AZ31 magnesium alloy sheet.     

AZ31 镁合金轧制-剪切-弯曲变形工艺数值模拟研究

目的研究温度和道次压下量的变化对AZ31镁合金轧制-剪切-弯曲变形工艺的影响规律。方法对AZ31镁合金轧制-剪切-弯曲变形过程进行数值模拟,探究变形过程中应力、应变分布规律。结果压下量越大,模具转角处累积的等效应变值越大;随着温度的升高,模具转角处等效应力逐渐减小,等效应变逐渐增大。结论试样在模具转角处发生了剧烈的塑性变形,研究结果为板材的制备提供了依据。