5A06铝合金环形连接框等温模锻坯料设计及工艺验证

Design on isothermal die forging billet for 5A06 aluminum alloy ring connecting frame and process validation

利用Deform有限元模拟软件研究了5A06铝合金环形连接框的成形过程,建立了立筋折叠形成过程模型,分析了坯料形状尺寸对筋顶折叠、成形速度均匀性和成形速度的影响规律,并进行了工艺验证。结果表明:对于与锻件随形的坯料,顶部折叠容易在成形速度快的位置产生;坯料轮廓尺寸减小时,锻件筋部成形速度和整体成形速度的均匀性均会下降,腹板处的等效应变增大,筋顶折叠程度在成形速度快且平直的筋处变化不大,在成形速度慢的筋处降低,拐折筋处的筋顶折叠程度则会由于侧壁流动现象而加剧。对于成形速度慢且存在拐折的位置,成形速度慢对折叠程度的降低和侧壁流动对折叠程度的加剧这两种影响相互竞争,侧壁流动现象的影响会随着坯料边缘到模具外侧壁的距离增大而逐渐占优,加剧折叠。

The forming process of 5A06 aluminum alloy ring connecting frame was studied by finite element simulation software Deform, and the forming process model of vertical rib folding was established. Then, the influence laws of shape and size for billet on rib top folding, forming speed uniformity and forming speed were analyzed, and the process verification was carried out. The results show that the top folding is easy to occur at the position of high forming speed for billet with the same shape as the forgings. With the decreasing of billet contour size, the uniformity for the forming speed of forgings rib and the overall forming speed reduce, the equivalent strain at the web increases, the folding degree of rib top does not change much at the position with fast forming speed and straight rib, but decreases at the rib with slow forming speed, and the folding degree of rib top at the turning rib is intensified due to the flow phenomenon of side wall. For the position with slow forming speed and inflection, the two influences of the slow forming speed resulting in the reduction of folding degree and the side wall flow resulting in the aggravation of folding degree compete with each other. The influence of the side wall flow phenomenon gradually dominates with the increasing of the distance between billet edge and outer wall of die, which aggravates the folding.