AA5B02 铝合金三通管充液成形工艺研究及参数优化

目的基于有限元数值模拟软件Dynaform对三通管的成形工艺进行优化。方法分析不同的初始压力、成形压力、轴向进给力、背压平衡力和合模力等对三通管成形的影响。根据成形过程进行模拟,得到分布应力图、厚向应变图、成形极限图等结果,根据模拟结果对零件的成形性进行分析,预测减薄破裂、起皱和回弹等缺陷。结果初始压力在防止侧推头将管坯推皱的前提下,取值应越小越好。成形压力和最大压力能保证减薄率、增厚率和成形度的要求即可。轴向进给对最终的成形质量影响较大。随着摩擦因数的增大,零件的减薄率不断增加,但是增厚率是先减小后增大。结论根据数值模拟的结果能够很好地优化三通管的成形工艺方案。

Optimization of Hydraulic Forming Process for Three-way Tube Based on Finite Element Simulation

Based on the finite element numerical simulation software Dynaform, the forming process of the three-way pipe is optimized. This paper analyzes the influence of different initial pressure, forming pressure, axial feed force, back pressure balance force and clamping force on the forming of the three pipe. According to simulate the forming process, distribution of stress diagram, the thick to strain diagram and forming limit diagram results. According to the simulation results of parts forming analysis and forecast minus thin rupture, wrinkling and springback defect. The results will prevent side push tube billet pushing under the premise to the initial pressure, the value should be as small as possible. molding pressure and the maximum can guarantee the thinning rate, thickening rate and the degree of forming requirements can be. The axial feed has a great influence on the final forming quality. With the increase of friction coefficient, the thinning rate of the parts is increasing, but the rate of increase is decreased first and then increased. Aaccording to the results of numerical simulation, the forming process parameters of the three way tube can be optimized.