铝合金板材不同连接工艺接头强度对比研究

分别利用自冲铆接、电阻点焊、压印连接技术对AA5052铝板进行连接,通过剖面直观检测法分析接头的成形质量,利用电液伺服试验机对接头进行静力学试验,分析接头的失效形式、失效载荷以及能量吸收值。结果表明:5052电阻点焊接头的失效载荷最高,约为自冲铆接头的1.1倍、压印接头的2.5倍;自冲铆接头的能量吸收值最高,约为电阻点焊接头的1.5倍、压印接头的18.8倍。

Formability of AA5052/polyethylene/AA5052 sandwich sheets

The formability of AA5052/polyethylene/AA5052 sandwich sheets was experimentally studied. Three kinds of AA5052/polyethylene/AA5052 sandwich specimens with different thicknesses of core materials were prepared by the hot pressing adhesive method. Then, the uniaxial tensile tests were conducted to investigate the mechanical properties of AA5052/polyethylene/ AA5052 sandwich sheets, and the stretching tests were carried out to investigate the influences of polymer core thickness on the limit dome height of the sandwich sheet. The forming limit curves for three kinds of sandwich sheets were obtained. The experimental results show that the forming limit of the AA5052/polyethylene/AA5052 sandwich sheet is higher than that of the monolithic AA5052 sheet, and it increases with increasing the thickness of polyethylene core.

基于响应曲面法的5052铝板自冲铆接成形工艺参数优化

以汽车电池包上两层2 mm料厚的AA5052-H32铝板的自冲铆接作为研究对象,基于DEFORM-2D软件及响应曲面法对自冲铆接工艺参数进行优化。借助中心设计组合法及有限元模拟结果,建立工艺参数与底切量之间的数学关系式,通过分析可得,模具宽度与模具深度对底切量的交互式影响最大。以模具宽度、模具深度以及模具凸台高度作为设计变量,将底切量作为铆接成形质量的优化目标,利用Design Expert软件进行优化,得出铝板自冲铆接的优化工艺参数为:模具深度为1. 45 mm,模具宽度为8. 95 mm,模具凸台高度为-0. 15 mm,底切量的响应值为0. 609 mm。此外,借助铆接设备对优化方案进行试验验证,底切量的试验值为0. 546 mm,试验值与响应值之间的相对误差为10. 34%,验证了响应面法应用于铝板自冲铆接成形工艺参数优化的准确性与可靠性。