多道次冲压与电磁渐进成形复合工艺下薄壁椭球件塑性变形机制

Plastic deformation mechanism of thin-walled ellipsoidal parts under multi-pass stamping and electromagnetic incremental forming composite process

为解决大尺寸变曲率薄壁椭球件常规成形易失稳起皱、尺寸超差和装备复杂等问题,提出了多道次冲压与采用环形线圈渐进成形制造薄壁椭球件的方法。采用ANSYS和ABAQUS软件联合分析了准静态冲压和线圈多次放电对零件不同区域应力应变状态和成形质量的影响。结果表明:环形线圈正对的板料区域在电磁力作用下发生高度变形,材料周向压应力出现高频振动并大幅度衰减,有效抑制了起皱产生。传统直接冲压高度为60 mm时,板料起皱位移可达7 mm。采用多道次冲压与电磁成形复合的方法,零件起皱被完全抑制。采用有限元模拟得到的最佳工艺参数,建立了实验工装并获得表面光滑的椭球形零件。

To solve the problems of instability wrinkling,excessive size differences and complicated equipment of large-size thin-walled ellipsoidal parts with variable curvatures,the method of manufacturing thin-walled ellipsoidal parts through multi-pass stamping and incre-mental forming with toroidal coils was proposed.The effects of quasi-static stamping and multiple coil discharges on the stress and strain state and forming quality of parts in different regions were analyzed by ANSYS and ABAQUS software.The results show that the sheet met-al area directly opposite the toroidal coil is highly deformed under the influence of electromagnetic force,and the circumferential compres-sive stress of the material appears high frequency vibration and greatly attenuates,which effectively inhibits wrinkling.When the tradition-al direct stamping height is 60 mm,the wrinkle displacement of the sheet metal reaches 7 mm.Wrinkling of parts is completely sup-pressed through the composite method of multi-pass stamping and electromagnetic forming.Based on the optimal process parameters ob-tained by finite element simulation,experimental tooling was established and ellipsoidal parts with a smooth surface were obtained.