大直径薄壁铝合金封头剪切旋压成形研究

Research on shear spinning for aluminum alloy head with large diameter and thin wall

应用ABAQUS/Explicit软件平台建立了大直径薄壁铝合金封头剪切旋压成形过程的有限元数值模型,通过数值模拟对大直径薄壁铝合金封头在剪切旋压过程中的应力应变分布进行了分析,获得了工艺参数对成形质量的影响规律为:随旋轮圆角半径R、旋轮进给比f及芯模转速n的增大,旋压件的不均匀变形度呈增大趋势;随旋轮圆角半径、旋轮进给比的增大,旋压件壁厚极小值逐渐减小;随芯模转速提高,壁厚极小值增大,旋压件壁厚极大值对工艺参数的变化不敏感。在此基础上确定了优化工艺参数为:R=12 mm,f=1 mm·r^(-1),n=40 r·min^(-1),并进行剪切旋压成形试验,获得了质量合格的Ф2600 mm大直径薄壁铝合金封头样件。

Based on the software ABAQUS/Explicit,a finite element model for shear spinning of aluminum alloy head with large diameter and thin wall was established,and the stress and strain distributions in shear spinning were obtained. Furthermore,the influences of process parameters on the forming quality were analyzed. The results show that the inhomogeneous deformation degree increases with the increases of roller tip radius（ R）,feed rate（ f） and mandrel rotation speed（ n）; the minimum wall thickness decreases with the increase of roller fillet radius and feed rate; the minimum wall thickness increases with the increase of rotational speed of the mandrel; the process parameters have no obvious effect on the maximum wall thickness. Based on the above study,the process parameters are optimized as R = 12 mm,f = 1 mm·r^（-1）,n = 40 r·min^（-1）,and the qualified part with large diameter Ф2600 mm and thin wall is obtained in the shear spinning experiment.