固溶成形工艺对6016铝合金组织及力学性能的影响

针对铝合金在室温下塑性差等问题,结合铝合金固溶处理特点,采用了固溶成形工艺制备零件。为获得6016-T6铝合金固溶成形最优工艺参数,利用电子拉伸试验机对6016-T6铝合金板进行不同加热温度及冷却方式的研究,分析了不同固溶工艺参数对其组织与力学性能的影响规律。结果表明,冷却速度对材料的组织性能影响较大,固溶工艺参数为550℃×5 min,水冷时,其抗拉强度可达到300 MPa以上。采用了上述工艺参数对铝合金后风档下横梁进行了测试验证,试制出合格的成形件,热冲压件力学性能可达308 MPa。     

Effect of die inlet geometry on extrusion of clover sections through curved dies: Upper bound analysis and experimental verification

The effect of die inlet and transition geometry on the extrusion loads and material flow for extrusion of clover sections were investigated and presented both theoretically and experimentally. For this purpose, four different die geometries including straight tapered and cosine transition profile and each of them having round and clover inlet geometries were chosen. In the experimental study, commercially pure lead was used because of its hot forming characteristic at room temperature. A newly kinematical admissible velocity field to analyze different profiles of extrusion dies of clover section from round bars was proposed by upper bound analysis. It is clear that the extrusion loads obtained from the theoretical analysis for various die inlet-die transition geometry combinations are in good agreement with the experimental results. Axis deviations of the parts which define the dimensional quality of the products were also investigated.     

FEM and metallurgical analysis of modified 6082 aluminium alloys processed by multipass ECAP: Influence of material properties and different process settings on induced plastic strain

Equal channel angular pressing (ECAP) is a very interesting method for modifying microstructure in producing ultra fine grained (UFG) materials. It consists of pressing test samples through a die containing two channels, equal in cross section and intersecting at an angle Φ. As a result of pressing, the sample theoretically deforms by simple shear and retains the same cross sectional area to repeat the pressing for several cycles.Two-dimensional and three-dimensional finite element method (FEM) simulations of both one and four ECAP passes of two modified aluminium alloys were performed in order to investigate the deformation state of processed workpiece and, moreover, the effect of different strain hardening rate, die geometry (in terms of variation of channel outer angle) and friction on deformation distribution and magnitude. FEM results showed a lower equivalent plastic strain on the outer side of both cross and longitudinal sections of the billets after one and four passes. Microhardness tests performed on the same sections of ECAP processed billets supported these findings. Moreover, FEM analysis indicated that a higher strain hardening rate means a greater strain inhomogeneity on cross section of the processed billet when the channel outer angle is small. As the channel outer angle increases and when friction is computed, the effect of strain hardening on strain inhomogeneity tends to decrease, while the die geometry and friction affect plastic strain distribution more than the hardening behaviour of the studied alloys.     

The finite element simulation of high-temperature magnesium AZ31 sheet forming

Finite element (FE) simulations will be vitally important to advancing magnesium alloy sheet forming technologies for vehicle component manufacturing. Although magnesium alloy sheet has been successfully formed into complex components at high temperatures, material constitutive model development for FE simulations has not kept pace with the needs of forming process design. This article describes the application of a new material constitutive model in FE simulations for hot forming of magnesium AZ31 alloy sheet. Simulations of forming both simple geometries from laboratory studies and complex parts from production trials are presented and compared with experimental results.     

Distortion in milling of structural parts

Cutting forces and thermal loads in milling may cause distortion in machined parts. Especially in the aerospace industry, distortion of thin wall structural parts in milling is one of the major problems. This problem can lead to increasing production costs or even rejection of manufactured parts. This article presents a new finite element modeling (FEM) approach to predict the milling induced distortion of Al7050 thin wall structural parts with complex geometries. The new approach is proposed for applying the estimated mechanical and thermal loads on the final part geometry. Milling experiments are performed on a complex frame geometry to validate the model.     

Optimum selection of variable punch-die clearance to improve tool life in blanking non-symmetric shapes

Punch-die clearance is a well-known parameter affecting both tool life and edge quality of parts in blanking and piercing. Selecting the optimum or best punch-die clearance can give a significantly longer tool life by minimizing tool wear. Previous studies have shown the effect of punch-die clearance on various sheet materials and thicknesses during blanking of round parts while non-round geometries are more commonly found in industrial applications. Therefore, in this study, the effect of part geometry is considered to select the ‘best’ punch-die clearance to minimize tool wear. In blanking non-round geometries, the punch and die undergo non-uniform wear, with higher wear observed in areas with sharp radii and abrupt changes in geometry. In the present study, the effect of punch-die clearance on punch stress for blanking various shapes is investigated using Finite Element (FE) analysis. The punch-die clearance that gives the lowest value of the punch stress for the different part geometries is identified. A method is developed to select a geometry dependent variable punch-die clearance to obtain more uniform wear on the punch, thereby increasing the punch and die life.     

Performance of powder-injection-molded W-4.9Ni-2.1Fe components

A 93 wt% W heavy alloy was injection molded into standard tensile test specimens and kinetic energy penetrators. Due to the relatively high activation energy of flow (124 kJ/mol), the rheological behavior of the molten feedstock was very susceptible to temperature variation. Using die sets with constant-volume die cavities, the tensile test specimens could be formed within a wide working window, whereas the penetrator could not be molded without defects because of different jetting phenomena during molding. The penetrator could be molded successfully using a die set whose die cavity progressively expanded during molding. The parts thus formed could subsequently be processed into intact components with full density and low carbon contents (<100 ppm). Their mechanical properties were comparable to or better than those of conventionally processed tungsten heavy alloys. Additional penetration test results indicated that powder injection molding was a viable route for processing high-performance tungsten heavy alloys.     

铝合金薄壁壳体件液态模锻成形过程的数值模拟

铝合金薄壁壳体件是航空航天及兵器工业上广泛采用的零件,但其制造工艺却长期得不到有效解决。文章采用Anycasting和DEFORM-3D软件,分别对充型阶段的凝固和塑性变形阶段进行了计算,并通过复合加载保证了零件使用性能上的要求。结果表明,模具和浇注温度越高,则凝固时间越长,且模具温度的影响要大于浇注温度的影响;在保证铝液完全充填型腔的前提下,充分考虑了模具的使用寿命和铝合金熔化温度的要求,进行了模具温度和浇注温度的优化;采用复合加载来代替简单加载可以有效地提高制件密度,使零件性能趋于均匀化。     

Macroscopic damage by the formation of shear bands during the rolling and deep drawing of magnesium sheets

Most magnesium parts for automobiles are currently produced by die casting, which allows for complex geometries. However, die casting has two significant disadvantages over wrought alloy sheets: it results in poorer mechanical properties and much rougher surfaces. An alternative production route for these parts is deep-drawn and joined magnesium sheets. This article describes an investigation into the effects of the deep-drawing process on magnesium alloys. For more information, contact Arne Rossberg, University of Hanover, Institute of Materials Science, Schoenebecker Allee 2, Garbsen, 30823 Germany; e-mail rossberg@iw.uni-hannover.de.     

A conical mandrel tube drawing test designed to assess failure criteria

Cold tube drawing is a metal forming process which enables to produce tubes with high dimensional precision. It consists in reducing tube dimensions by pulling it through a die. Tube outer diameter is calibrated by a die and the tube inner diameter and thickness are calibrated by a mandrel. One of the major concern of metal forming industry is the constant improvement of productivity and product quality. In the aim of pushing the process to the limit the question is how far the material can be processed without occurrence of failure. In the present study, a long conical mandrel with a small cone angle was designed in order to carry out drawing tests up to fracture with experimental conditions very close to the industrial process. The FEM of the process was built in order to access the local stress and strain data. A specific emphasis was put on the friction characterisation. For that purpose force measurement during the conical mandrel experiments enabled to characterise a pressure dependent friction coefficient constitutive law by means of an inverse analysis. Finally, eleven failure criteria were selected to study the drawability of cobalt–chromium alloy tubes. The assessment of failure criteria based on damage variables or damage accumulation variables involved their calibration on uniaxial tensile tests. The experimental studies were completed by SEM fractography which enabled to understand the fracture locus and the propagation direction of the fracture.     

Broaching tool design through force modelling and process simulation

Tool design is the most critical part of broaching operations as the key process parameters are permanently defined by the cutter geometry. The main objective of this study is to develop methods for increased productivity of broaching processes through improved tool design based on force simulations. A thermo-mechanical force model is applied to broaching operations with complex tool geometries. Intermediate teeth definition and generation algorithms which are essential parts of broaching process simulations are developed. Simulation results are experimentally verified, and improved tool designs are demonstrated.     

Influence of process-related oxide formation during shaping of aluminum fiber mats in the mushy state

Conventional semi-solid-methods offer a variety of options concerning the production of parts with appropriate mechanical properties as well as complex geometries. However, they are only partly suitable for the production of large-area thin-walled components. When using a globular pre-material, segregation occurs increasingly with increased deformation. For this reason a novel metallic flexible fiber material, which can be already inserted extensively in the die, is used as feedstock for the first time. After transferring the material into the semi-solid state, it will be shaped by using a simple lifting tool. Due to the shape of the flexible feedstock the danger of introducing additional oxides emerges which may cause a disadvantage for mechanical properties of the finished parts. However, the flexible feedstock provides the opportunity to reduce the degree of deformation as well as the avoidance of segregation by mainly shaping via height. Finally, these fibers can be crimped to a homogeneous structure. During the transferring process into the semi-solid state additional process-related oxides are formed. These oxides on the fiber surfaces create an influence the connection of fibers among themselves. In order to prevent the formation of process-related oxides a protective gas atmosphere can be used, which leads to slight improvements of mechanical properties. Furthermore, additional process steps have to be examined in order to distribute the oxides in the microstructure finely.     

FGH96合金挤压变形工艺数值模拟

利用DEFORM-3D有限元软件对FGH96合金挤压工艺进行了研究,通过正交试验设计的方法研究了坯料温度、挤压速度、摩擦条件、模具锥角和模具工作带长度对挤压载荷的影响;同时具体研究了挤压速度和模具锥角对挤压载荷和挤压件温度的影响,以及不同条件下的等效应变的分布规律,并对挤压过程中可能出现的缺陷进行了预测,为工艺实验的研究提供了参考.     

Extrusion through controlled strain rate dies

The workability of a material during deformation processing is determined by (a) the die geometry which, in turn, determines the flow field during deformation, and, (b) the inherent workability of the material under the imposed processing conditions of strain rate and temperature. Most common alloys have good inherent workability and can be successfully formed over wide ranges of temperature and strain rate. Products can be successfully formed from these alloys even with dies which impose large variations in strain rate during deformation. However, many of the new alloys and composites can be deformed only in very narrow processing regimes, and control of the strain rate during deformation of such materials becomes important. For example, extrusion of a whisker-reinforced aluminum alloy composite is possible only when the strain rate is controlled to within one order of magnitude. This paper describes the development of a method for obtaining preliminary shapes of controlled strain rate extrusion dies, a special case being the constant strain rate die. The theoretical basis for such die design processes is presented, followed by some examples of die geometries. Since this design procedure ignores the material flow properties, the designed die shapes must be verified using the finite element method or physical modeling. Results of simulations with the program ALPID are also presented.     

Effect of target-fixture geometry on shock-wave compacted copper powders

In shock compaction with a single gas gun system, a target fixture is used to safely recover a powder compact processed by shock-wave dynamic impact. However, no standard fixture geometry exists, and its effect on the processed compact is not well studied. In this study, two types of fixture are used for the dynamic compaction of hydrogen-reduced copper powders, and the mechanical properties and microstructures are investigated using the Vickers microhardness test and electron backscatter diffraction, respectively. With the assistance of finite element method simulations, we analyze several shock parameters that are experimentally hard to control. The results of the simulations indicate that the target geometry clearly affects the characteristics of incident and reflected shock waves. The hardness distribution and the microstructure of the compacts also show their dependence on the geometry. With the results of the simulations and the experiment, it is concluded that the target geometry affects the shock wave propagation and wave interaction in the specimen.     

基于响应面法的铝合金间接挤压铸造工艺研究

为研究间接挤压铸造工艺,选取ZL101铝合金,以孔隙率为指标,首先通过单因素实验,分析了挤压压力、模具温度与比例系数3个因素对孔隙率的影响。然后采用Box-Behnken实验设计方法来设计响应面实验,建立了间接挤压铸造工艺参数与孔隙率相互关系的预测模型,方差分析结果表明,实验结果和数学模型拟合良好。通过对各个因素交互作用的响应面进行分析,得知模具温度和挤压压力对孔隙率的影响存在显著的交互作用,模具温度和比例系数、比例系数和挤压压力对孔隙率的影响不存在显著的交互作用。通过对环形件浇注系统的直浇道边缘部位进行金相检测分析,得知由于压力的施加,会使已经凝固的金属壳层发生不均匀的塑性流动。     

模具结构对AZ91镁合金挤压成形性能的影响

AZ91镁合金由于强度高、流动性好等特点,通常用作铸造合金。研究该合金合理的挤压温度、挤压速度及模具结构,对提高其塑性成形性能、开发高强度变形镁合金有重要的理论和实际意义。文章通过热模拟试验研究了AZ91镁合金应力应变关系,确定了最佳变形温度。在此基础上,采用三维有限元法模拟分析了不同挤压速度、模具结构对挤压过程温度场、速度场及应力场的影响。结果表明,采用锥模和流线模时,当定径带长度为15mm~20mm时,可在挤压速度达到5mm/s的条件下成形出表面光滑无裂纹的镁合金棒材;而采用平模挤压时,当定径带长度为10mm~20mm时,获得良好表面质量的挤压速度达到2.5mm/s。在650t的卧式挤压机上,进行了该合金的挤压实验,实验结果与模拟结果相吻合。     

Numerical simulation on forging process of TC4 alloy mounting parts

1Introduction The TC4alloy mounting part is an important part of aeronautic engine.Currently,these mounting parts are mainly manufactured by metal cutting,which is expensive and requires a lot of manufacturing time.Furthermore,in this way the forging flow…     

铝合金薄壁筒滚珠旋压成形分析

作为一种连续局部塑性成形工艺,滚珠旋压被应用于制造铝合金薄壁筒形件。介绍了滚珠旋压的基本原理,以塑性力学为基础,分析力学参数对旋压件成形性的影响。实验中通过采用LF2和LY12两种铝合金筒坯,获得金属材料的塑性和屈服强度对旋压件可旋性影响的一般规律。最后研究咬入角对金属材料稳定流动的影响,并通过实验获得了合理的咬入角值。     

Laser ultrasonic characterisation of branched surface-breaking defects

Surface-breaking defects often have a geometry which is more complicated than the ‘normal slot’ used in many calibration tests, and this geometry will affect the reflection and transmission of ultrasonic surface waves incident on the defect. We present here measurements on defects with varied branched geometries, designed to simulate stress corrosion cracking (SCC) type defects, characterising the geometry using laser-based ultrasonic generation and detection of Rayleigh waves. We show the behaviour of the near-field enhancement and the far-field reflection as a function of branch position and length, and signal analysis which can be used to gain further information for characterising the defect geometry. The experimental results and finite element method (FEM) models presented in this paper highlight the potential of this technique to test components prone to developing SCC, in order to identify and characterise surface-breaking defects.