Process Optimization and Experimental Study on Hydroforming Process of Box-shaped Parts
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摘要: 本文主要研究充液拉深成形技术在复杂异形长法兰类盒形件成形过程中的应用, 首先对该类零件的材料进行了力学性能和成形性能测试分析, 获取材料的成形极限, 确定了充液拉深成形方案; 建立了盒形件的有限元仿真模型, 模拟了盒形件在充液拉深成形过程中材料的壁厚变化情况, 通过成形缺陷分析对关键工艺参数低压充液时间TLP、整形时间TIP、最大压边力Fmax、液体流速Vel%, 最大成形力Pmax及时效时间Tw等进行了重新设计, 并通过数值模拟和试验验证相结合的方法优化了工艺参数; 最终, 完成了盒形件充液拉深成形流程再造, 确定出最优的工艺参数, 并成功实现盒形件的充液拉深成形, 使其制造效率和产品质量大幅提升, 为低塑性、难变形材料盒形件的批量制造奠定了工艺基础。Abstract: This paper mainly studies the application of hydroforming technology in the forming process of complicated long flange box-shaped parts. At first, the mechanical properties and forming properties of the materials of this kind of parts are tested and analyzed, the forming limit of the material is obtained, and the hydroforming scheme is determined. Then, the finite element simulation model of the box-shaped part is established, and the variation of the material wall thickness during hydroforming is simulated. The key process parameters, low pressure filling time TLP, plastic time TIP, maximum blank holder force Fmax, liduid flow rate Vel%, maximum forming force Pmax and aging time Tw, were redesigned by forming defect analysis. The process parameters were further optimized by the combination of numerical simulation and experimental verification. Finally, the hydroforming process of the box-shaped parts was reconstructed, and the optimal process parameters were determined. This study greatly improves the manufacturing efficiency and product quality, and lays a technological foundation for the hydroforming of the box-shaped parts with low plasticity and difficult deformation.
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Key words:
- hydroforming /
- numerical simulation /
- simulation analysis /
- process parameters
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表 2 成形工艺参数
简称 Pmax/Bar TLP/s TIP/s Fmax/kN Vel% 含义 最大成形液力 低压充液时间 高压充液时间 最大压边力 液体流速 决定意义 成形极限 低压进料时间 高压整形时间 起皱控制 压力上升速度 制定准则 材料成形力 尽可能大 合理范围内 合理范围内 适中 
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表 4 第一次充液工艺参数优化
组序 Pmax/Bar Vel% 第一次充液拉深成形试验件 最大减薄率/% 变形程度 1 280 30% 
17.3 较大 2 280 40% 17.8 较大 3 285 30% 18.7 较大 4 290 40% 20.5 大
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表 6 盒形件充液拉深成形最优工艺参数
充液 Pmax/Bar TLP/s TIP/s Fmax/kN Vel% Tw/min 第一次充液 280 10 3 300 30% - 第二次充液 280 10 5 300 30% 45
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