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超塑气胀成形工艺是复杂薄壁零件成形的主要技术.以5083铝合金为研究对象，利用Marc有限元软件对动车车窗的超塑气胀成形工艺进行研究，选择合适的正反胀时间和压力，设计了3套不同的反胀模具(底面左上端圆角大小不同以及左端是否有凸槽),依次进行热冲压、反胀及正胀有限元分析，最终得出正确的超塑气胀成形模具.结果表明：反胀过程中储料的多少对成形件有显著影响；其中两种成形件的右边储料过多，刚性太大，正胀时难以变形，出现褶皱缺陷，而另外一种成形件由于模具左端设有凸槽减少了储料，刚性也减小，故易于变形且无明显缺陷；成形件最小壁厚为2.496 mm,位于车窗内边缘棱边处，最大减薄率为37.6%,与模具贴合良好且质量稳定，整体壁厚分布均匀.
Abstract：Superplastic air bulging forming process is the main technology for forming complex thin-walled parts. Taking 5083 aluminum alloy as the research object, using Marc finite element software to study the superplastic air bulging forming process of railway windows, selecting the appropriate direct-reverse bulging time and pressure, designing three different sets of reverse bulging molds(with different sizes of rounded corners at the upper left end of the bottom surface and whether there is a convex groove at the left end), and carrying out the finite element analysis of hot stamping, reverse bulging and direct bulging in turn, so that we can finally arrive at the correct superplastic air bulging forming molds. The results show that: the amount of material storage in the process of reverse bulging has a significant effect on the molded parts; two of the molded parts have too much material storage on the right side, the rigidity is too large, and it is difficult to deform and wrinkle defects appear in direct bulging, while the other molded part is equipped with convex grooves on the left side of the mold to reduce the storage of material, so the rigidity is also reduced, and it is easy to deform and has no obvious defects. The minimum wall thickness of the molded part is 2.496 mm, which is located at the inner edge of the window, and the maximum thinning rate is 37.6%. The molded part fits well with the mold and the quality is stable, and the overall wall thickness is evenly distributed.
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基本信息:
DOI：10.14186/j.cnki.1671-6620.2023.05.015
中图分类号:U270.6
引用信息:
[1]王国峰 ,李源池 ,周彤旭 ,等.5083铝合金动车车窗超塑气胀成形工艺[J].材料与冶金学报,2023,22(05):505-510.DOI:10.14186/j.cnki.1671-6620.2023.05.015.
基金信息:
国家自然科学基金资助项目(51875122)
2023-09-15
2023-09-15