5154铝合金小尺寸产品的轧制剪切加工实践

Processing practice on rolling and shearing of small size product for 5154 aluminum alloy

针对5154铝合金小尺寸产品铸造加工过程中生产效率低下且易产生缩孔、裂纹等缺陷的问题,提出了轧制配合剪切的加工方式。为实现受限空间内保护气氛下的多次轧制,拟采用单槽多道次轧辊。按照等压下率原则设定总轧制次数为6道次,计算得到每道次压下率为27%,从而确定了各道次压下量。根据5154铝合金的物理性质、压下量及其他影响因素,计算得到系统需提供的轧制力为1195600 N,轧制力矩为71721 N·m。试验结果显示,板坯板形良好,无瓢曲、起拱、波浪、侧弯等板形缺陷。根据最终产品尺寸要求,设计出横向与纵向双剪刃协同运动的剪切机构,参考抗剪强度计算出所需剪切力为123120 N,通过比较两种剪切方案所得产品的状态确定了最优剪切方案。最终产品满足技术规程规定的小于9 mm×45 mm的要求,有效地解决了生产中存在的问题。

For the problems of low production efficiency and easy generation of shrinkage holes,cracks and other defects in the casting process for 5154 aluminum alloy small-size products,a rolling and shearing processing method was proposed.In order to achieve multiple rolling under the protective atmosphere in a confined space,a single-groove and multi-pass roller was adopted.According to the principle of equal reduction rate,the total number of rolling times was set to six passes,and the reduction rate of each pass was calculated to be 27%,so as to determine the reduction amount of each pass.According to the physical properties,reduction amount and other influencing factors of 5154 aluminum alloy,it is calculated that the rolling force that the system needs to provide is 1195600 N,and the rolling torque is 71721 N·m.The test results show that the slab is in good shape without buckling,arching,waves,side bending and other sheet shape defects.According to the size requirements of the final product,the shearing mechanism with the coordinated movement of transverse and longitudinal double shear blades was designed,and the required shearing force was calculated to be 123120 N by reference to the shear strength.The optimal shearing scheme was determined by comparing the states of the products obtained from the two shearing schemes.Thus,the final product meets the requirement of less than 9 mm×45 mm specified in the technical regulations,which effectively solves the problems existing in the production.