铝合金杯类零件双面及侧面成形工艺研究

对于2A12铝合金阶梯形杯形件的塑性成形,传统工艺是由每一级的台阶单工序成形,积累为最终的多阶梯成形,由于多次加热、多套模具、多道次挤压、多道次定位放置的误差积累会造成尺寸精度低、能耗高、效率低、模具导柱和导套不耐高温的缺陷。对于杯形件的侧壁直肋与台阶外形,用传统工艺挤压内、外圆角(小于R0.5mm时)很难完成。通过有限元模拟和工艺优化,本文采用凹模内不脱模连续挤压、控制流向顺序的方法,以及采用十字键模口导向结构,形成了一次加热、一次放置毛坯成形多台阶、小圆角的新工艺。该工艺缩短了工时,提高了产品性能和材料利用率,为小圆角多台阶类型的零件实现短流程的挤压工艺转化提供了参考依据。

Forming process research on double-faced and flank of aluminum alloy cup parts

For forming of the cup-shaped piece for 2A12 material with a ladder-shape,the traditional forming process is a single process that step by step to accumulate into a multi-ladder through repeated heating,which will lead to low dimensional precision,high energy consumption,low efficiency,low heat resistance of die guide post and guide sleeve for using several sets of molds,multi-channel extrusion,repeated positioning error accumulation.For straight sidewall rib and step shape in the traditional extrusion,it is very difficult to form rounded corners less than R0.5 mm.Through finite element simulation and process optimization,a new technology was gained to form ladder-shaped and small rounded corners by once heating,once placing workpiece using cross key die mouth oriented structure and method of continuous extrusion to control the order of the flow direction.With new technology the working hours are reduced,product performance and material utilization are improved,which provide a reference to form small rounded corner and multi-step products with short process transformation technology.