单点增量成形U型金属波纹管的试验研究

THE EXPERIMRNTAL RESEARCH ON SINGLE POINT INCREMENTAL FORMING U-SHAPED METAL BELLOWS

分析了工业领域中塑性成形管件加工的工艺制造需求和研究现状,介绍了单点增量成形金属波纹管的工作原理。为获得工艺参数对成形过程及成形质量的影响规律,建立了基于Abaqus/Explicit的U型金属波纹管单点增量成形有限元模型,搭建实验平台,开展了试验研究。针对T3紫铜材料,通过不同加工工艺参数下的试验,以波纹成形高度为成形质量检测指标,获得了单点增量加工过程中层间距、主轴转速、轴向进给速度对加工结果的影响规律。结果表明,主轴转速对金属波纹管成形波纹高度影响最大,其次为层间距,而轴向进给速度对成形质量影响不显著。在主轴转速为450 r/min,层间距为0.25 mm,轴向进给速度为0.2 mm/r时为最优工艺参数,金属波纹管单点增量成形质量好、精度高。通过仿真和试验结果对比,验证了此优化结果的可靠性。为进一步应用该工艺提供了参考。

The manufacturing requirements and research status of plastic forming pipe fittings in the industrial field are analyzed.The working principle of single point incremental forming metal bellows is introduced.In order to obtain the influence of process parameters on the forming process and forming quality,the finite element model of U-shaped metal bellows of single point incremental forming was established by the finite element analysis software ABAQUS/Explicit.The experimental platform was built and the experimental research was carried out.The T3 red copper was selected as material,through the experiments under different processing parameters,the corrugated forming height is used as the forming quality testing index,and the effect of the interlayer space,spindle speed and axial feed speed on the processing results in the process of single point incremental machining is obtained.The results show that the spindle speed has the greatest impact on the corrugated height of the metal bellows,followed by the interlayer space,and the axial feed speed has no significant influence on the forming quality.The single point incremental forming of metal bellows is of good quality and high precision when the spindle speed is 450r/min and the interlayer space is 0.25mm axial feed speed of 0.2mm/r.The reliability of the optimization results is verified by simulation and experimental results.It provides a reference for the further application of the process.