基于数值模拟的铝合金四通管双向挤压精密成形工艺优化

Optimization on two-way extrusion precision forming process for aluminum alloy four-way pipe based on numerical simulation

针对四通管传统成形工艺的不足,提出一种铝合金四通管的双向挤压精密成形工艺。首先,根据铝合金四通管双向挤压精密成形工艺的原理,在三维软件SolidWorks中建立坯料和成形工具的三维模型,将其导入Deform-3D中建立数值模拟的有限元模型,进行初步模拟分析。然后,根据文献调研和初步模拟分析结果确定影响零件成形质量的主要因素为坯料温度、挤压速度和模具预热温度。采用正交试验方法对铝合金四通管双向挤压精密成形工艺进行试验设计,以坯料温度、挤压速度和模具预热温度作为试验因素,以最大等效应力和最大冲头载荷作为优化目标,利用Isight软件建立了响应面近似模型并求解得到铝合金四通管双向挤压精密成形最优的工艺参数组合为:坯料温度为374℃、挤压速度为5 mm·s^(-1)、模具预热温度为281℃。最后,采用优化的参数组合进行模拟验证,得到优化后的四通管零件无成形缺陷,且其最大等效应力和最大冲头载荷与多目标优化结果的误差小于3%。模拟结果表明,所提的四通管双向挤压精密成形工艺可行,可有效提高四通管的生产效率和材料利用率。

Aiming at the shortcomings of the traditional forming process for four-way pipe,a two-way extrusion precision forming process of aluminum alloy four-way pipe was proposed.Firstly,according to the principle of the two-way extrusion precision forming process of aluminum alloy four-way pipe,the three-dimensional models of billet and forming tools were established by 3D software SolidWorks,and the finite element model of the numerical simulation was established by Deform-3D to simulate and analyze preliminaryly.Then,according to the literature research and preliminary simulation results,billet temperature,extrusion speed and mold pre-heating temperature were taken as the main factors affecting the forming quality of parts,and the two-way extrusion precision forming process of aluminum alloy four-way pipe was test designed by the orthogonal experiment method.Furthermore,taking the billet temperature,extrusion speed and mold preheating temperature as the test factors,and taking the maximum equivalent stress and the maximum punch load as the optimization objectives,the response surface approximation model was established by software Isight,and the optimal process parameters combination of the two-way extrusion precision forming process of aluminum alloy four-way pipe was obtained as the billet temperature of 374℃,the extrusion speed of 5 mm·s^(-1),and the mold pre-heating temperature of 281℃.Finally,the optimized parameters combination was verified by the simulation,and it was found that the optimized four-way pipe parts had no forming defects,and the error between the maximum equivalent stress and the maximum punch load and the multi-objective optimization results was less than 3%.The results show that the proposed two-way extrusion precision forming process of four-way pipe is feasible and effectively improve the production efficiency and material utilization of the four-way pipe.