薄壁铝合金封头旋压成形工艺研究

Study on the spinning process of thin-walled aluminum alloy vessel head

应用ANSYS软件对薄壁铝合金封头冷旋压成形过程进行了弹塑性有限元数值模拟。通过对球冠部分和翻边部分第1道次各阶段的应力应变分析,揭示了其成形时的塑性变形流动规律,并分析了几种主要工艺参数对成形质量的影响规律及失效问题产生的原因。研究结果表明:薄壁铝合金封头冷旋压成形的主要失效形式是翻边部分的外缘起皱,控制皱纹产生的有效方法是采用弯边措施增加外缘法兰的刚度、选择合适的第1道次倾角和采用较小的进给比。

On the basis of the elasto-plastic finite element method, ANSYS software is applied in order to simulate spinning deformation of the vessel head with thin wall thickness. The distribution of stress and strain on the sphere coronal and the first pass corner is obtained so as to acquire the basic law of plastic deformation of the spun workpiece. Analysis is laid on the influence of several main process factors on forming quality as well as failure problems of the spun part. The results show that the main failure pattern of cold spinning deformation of the vessel head with thin wall thickness is the wrinkling of outer flange. The effective measures which are taken to avoid wrinkling include increasing the rigidity of outer flange by bending edge, selecting the appropriate obliquity of the first pass and adopting small feed ratio.