5A02铝合金管端旋转冲压双扩口成形过程精确预测

Precise prediction of double flaring forming process of 5A02 aluminum alloy tube end by rotating-stamping

针对双扩口管端头难以夹持成形的问题,采用了双扩口管端旋转冲压成形工艺,降低了双扩口管端头的成形力。建立了旋转冲压双扩口成形与回弹全过程的有限元模型,实现了管端双扩口成形的精确预测。结果表明:相比于冲压双扩口,旋转冲压双扩口成形可显著降低夹持凹模所需要提供的夹持力(从18 kN降低至1 kN),低至前者的10%以下;管端头扩口颈部不贴模现象主要发生在单扩道次,且不明显;内翻道次成形后,管端的变形状态对双扩口管的最终成形质量有着显著的影响。当采用2.0 mm≤圆角半径r≤3.0 mm、85°≤半锥角φ≤90°的旋轮进行内翻时,可成形出效果较好的双扩口管端。

For the problem that it is difficult to clamp and form the end of double flaring tube,the rotating-stamping process of double flaring for tube end was used to reduce the forming force of double flaring for tube end.The finite element model of the whole process consisted of double flaring forming by rotating-stamping and springback was established,which achieved accurate prediction of the double flaring forming for tube end.The results show that the clamping force required by holding the die can be reduced significantly to less than 10%(from 18 kN to 1 kN)for double flaring forming by rotating-stamping compared with double flaring forming by stamping.The phenomenon of the badly fittability in the neck of flaring is not obvious,which mainly occurs in the single flaring pass.The deformation state of the tube end after the inversion pass forming has a significant influence on the quality of the double flaring tube.Using the spinning roller of 2.0 mm≤radius of rounded corners r≤3.0 mm and 85°≤half of cone angleφ≤90°to turn inward,a double flaring tube end of better quality can be formed.