大型铝合金构件的多道次电磁渐进成形

Multi-pass electromagnetic incremental forming of large scale aluminum alloy components

电磁渐进成形具有提高材料成形性能和减小回弹等优点,为大型铝合金构件的成形制造提供了一种全新的工艺方法。以运载火箭用大型铝合金贮箱箱底构件的典型缩比件为研究对象,使用自主设计的电磁渐进成形工装验证了所建立的多道次电磁渐进成形模型,通过模拟确定了多道次电磁渐进成形的层高和层数,并通过多道次电磁渐进成形实验确定了符合精度要求的贮箱箱底缩比件。探讨了大型铝合金构件多道次电磁渐进成形的工艺可行性,揭示了成形过程中的塑性变形行为,并建立了成形过程的控制方法,研究结果可为电磁渐进成形工艺在大型铝合金构件中的应用奠定理论基础。

Electromagnetic incremental forming(EMIF) has the advantages of improving material formability,reducing springback,etc.,which provides a new process method for the forming and manufacturing of large scale aluminum alloy components.For the typical scaled down part of large scale aluminum alloy storage tank bottom component of a carrier rocket,the finite element model of multi-pass EMIF was validated by self-designed fixture of EMIF.Then,the height and number of layers in the multi-pass EMIF were determined by simulation,and the scaled down part of storage bottom that met the accuracy requirements was tested by the multi-pass EMIF experiment.Furthermore,the process feasibility of multi-pass EMIF for large scale aluminum alloy components was explored,the plastic deformation behavior of forming process was revealed,and the control method of forming process was established,which laid a theoretical foundation for the application of EMIF in the large scale aluminum alloy components.