高强铝合金异形复杂构件预成形优化设计

Preforming optimization design on high-strength aluminum alloy special-shaped complex components

针对7075高强铝合金异形复杂构件常规挤压成形中的折叠、载荷过大及变形不均匀等缺陷,提出凹面毛坯预成形设计方法。采用Deform-3D有限元软件分析预成形毛坯凹面方向及凹面尺寸参数对成形载荷、变形均匀性的影响,确定优化的预成形凹面结构及尺寸参数,最后对优化结果进行物理实验验证,并取样进行了夏比缺口冲击实验与拉伸实验。实验结果表明:与传统挤压成形工艺比较,采用双凹面预成形毛坯的终成形载荷将降低39%以上,等效应变差值明显降低,变形更加均匀,且冲击韧性、抗拉强度与伸长率均有所提高。经成形实验验证了优化设计方案的合理性,研究结果将为高强铝合金异形复杂构件的预成形优化设计提供理论参考。

For the defects of folding,over-loading and uneven deformation in the conventional extrusion of high-strength 7075 aluminum alloy special-shaped complex components,the preforming design method of concave billet was proposed. Then,the influences of concave direction and dimension parameters of preformed billet on forming load and deformation uniformity were analyzed by finite element analysis software Deform-3 D,and the optimized structure and dimension parameters of preformed concave were determined. Finally,the optimization results were verified by physical tests,and Charpy notched impact test and tensile test were conducted by taking samples. The experiment results show that compared with the traditional extrusion process,the final forming load of billet by the double concave preforming reduces more than39%,the equivalent strain difference significantly reduces,the deformation is more uniform,and the impact toughness,tensile strength and elongation improve respectively. Thus,the rationality of the optimized design scheme is verified by the forming test,and the research results provide a theoretical reference for the preforming optimization design of high-strength aluminum alloy special-shaped complex components.