铝合金异形件充液成形失稳控制策略

Investigation into the failure control during hydroforming of special-shaped aluminum sheet part by finite element analysis and experiment

对2024-O铝合金异形件的充液成形过程进行研究,讨论充液成形过程中可能出现的失稳形式,通过数值模拟与实验分析液室压力和压边间隙对充液成形的影响,优化工艺参数,提出了控制失稳的措施。结果表明,长边法兰起皱和短边侧壁断裂是成形的主要失效形式,采用合理的压边间隙、液室压力加载路径,可以有效控制法兰起皱和侧壁破裂,实验结果与数值模拟符合较好。

The hydroforming process of an aluminum alloy 2024-O special-shaped sheet part was investigated.The failures types may occur in the process were discussed.The effects of the gap of the blank holder and the pressure in the die cavity loading on the formed part were analyzed by numerical simulation and experiment.The process parameters were optimized and measures of failure controlling were presented.The results show that long side flange wrinkle and short side wall crack are the main failure types in hydroforming,suitable blank holder gap and die cavity pressure loading curve can prevent wrinkle and crack.The experimental results keep reasonable agreement with the numerical one.