大径厚比薄壁变曲率构件充液拉深成形技术

Hydro-drawing technology for thin-walled variable curvature part with large diameter to thickness ratio

为提高大径厚比变曲率薄壁件的成形质量,对充液拉深技术开展了分析,利用CAE技术和试验相结合的方法,分析了充液拉深过程中材料变形机理和工艺参数的影响规律。为成形良好产品,分析了板料尺寸、液室压力及圆角半径等参数对成形的影响,并通过试验得到优化的工艺参数,同时设计了带α角的分体模具结构,实现了降低压边力、减小起皱风险、减少液体容积的有益效果。结果表明,当板料尺寸为Φ1250 mm,液室压力为5~7 MPa,圆角半径为30 mm时,成功研制了变曲率构件并通过了尺寸检验,产品的外形尺寸精度由0.8 mm提升至0.4 mm,并降低了零件的减薄率,为薄壁构件精密制造水平的提升提供了技术支持。

In order to improve the forming quality of thin-walled variable curvature part with large diameter to thickness ratio, the hydro-drawing technology was analyzed, and the deformation mechanism of material and the influencing laws of process parameters were investigated by the method of combining CAE technology and experiment. Then, in order to form a better part, the influences of parameters such as sheet size, chamber pressure and fillet radius on the forming were analyzed, and the process parameters were optimized by experiment. At the same time, the split die structure with angle α was designed to realize the beneficial effects of effectively reducing the blank holder force, wrinkling risk and liquid volume. The results show that the variable curvature part is successfully formed with the sheet size of Φ1250 mm, the chamber pressure of 5-7 MPa and the die fillet radius of 30 mm, and pass the dimensional inspection. The profile dimensional accuracy of product is improved from 0.8 mm to 0.4 mm and reduces the thinning ratio of part, which provides technical support for the improvement of the precision manufacturing level for thin-walled part.