2024铝合金难成形高锥盒形件充液成形数值模拟

Simulation Research on Hydroforming of Hard Forming Deep Taper-shaped Part of 2024 Aluminum Alloy

目的解决锥盒形件传统拉深成形十分困难,废品率高,成形质量差的问题。方法介绍了充液成形工艺的2种方式,即主动式充液成形和被动式充液成形,并利用有限元软件Dynaform对各充液成形方案进行了数值模拟。结果通过模拟分析,明确了2种充液成形方式的优缺点,提出了被动式-主动式充液成形方案,并进行了数值模拟验证;合理的预成形凸模圆角大小是A侧长边底部圆角R=40 mm,B侧长边底部圆角R=30 mm,其他底部圆角R=15 mm。结论充液成形技术与传统拉深相比,具有一定的优势;被动式-主动式充液成形方案数值模拟结果良好;预成形形状对终成形有很大的影响,改变预成形凸模圆角可控制各侧补料量。

Objective To solve the problem of forming a taper-shaped part by traditional deep drawing, which has high rejection rate and poor forming quality. Methods The two types of sheet hydroforming were introduced, namely active bydroforming and passive hydroforming. Each hydroforming scheme was numerically simulated by the finite element software Dynaform. Results The advantages and disadvantages of the two types of sheet hydroforming were investigated by numerical simulation. And the passive-active hydroforming scheme was proposed. This process was validated by numerical simula- tion. The bottom fillet radii of the preforming punch were reasonable when the bottom fillet radius of A long side and B long side was 40 mm and 30 mm, respectively, and the others were 15 mm. Conclusion In contrast with traditional deep drawing, hydroforming was advantageous. The simulation result of the passive-active hydroforming was good. The shape of preforming punch which could control feed of every side with different radii has a great impact on the final forming.