The microstructure of the thin-walled tubes with high-strength aluminum alloy determines their final forming quality and performance. This type of tube can be manufactured by multi-pass hot power backward spinning pro...The microstructure of the thin-walled tubes with high-strength aluminum alloy determines their final forming quality and performance. This type of tube can be manufactured by multi-pass hot power backward spinning process as it can eliminate casting defects, refine microstructure and improve the plasticity of the tube. To analyze the microstructure distribution characteristics of the tube during the spinning process, a 3D coupled thermo-mechanical FE model coupled with the microstructure evolution model of the process was established under the ABAQUS environment. The microstructure evolution characteristics and laws of the tube for the whole spinning process were analyzed. The results show that the dynamic recrystallization is mainly produced in the spinning deformation zone and root area of the tube. In the first pass, the dynamic recrystallization phenomenon is not obvious in the tube. With the pass increasing, the trend of dynamic recrystallization volume percentage gradually increases and extends from the outer surface of the tube to the inner surface. The fine-grained area shows the states of concentration, dispersion, and re-concentration as the pass number increases. .展开更多
Thin-walled aluminum alloy tube numerical control (NC) bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of...Thin-walled aluminum alloy tube numerical control (NC) bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of the parameters was proposed based on the finite element (FE) simulation, and the significance analysis of the processing parameters on the forming quality in terms of the maximum wall thinning ratio and the maximum cross section distortion degree was implemented using the fractional factorial design. The optimum value of the significant parameter, the clearance between the tube and the wiper die, was obtained, and the values of the other parameters, including the friction coefficients and the clearances between the tube and the dies, the mandrel extension length and the boost velocity were estimated. The results are applied to aluminum alloy tube NC bending d50 mm×1 mm×75 mm and d70 mm×1.5 mm×105 mm (initial tube outside diameter D0 × initial tube wall thickness t0 × bending radius R), and qualified tubes are produced.展开更多
Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness.They can be produced at room temperature by the electrohydraulic for...Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness.They can be produced at room temperature by the electrohydraulic forming process.In the present study,the influence of the related parameters on the forming quality of a 6063 aluminum alloy sinusoidal corrugation tube has been assessed.In particular,the orthogonal experimental design(OED)and central composite design(CCD)methods have been used.Through the range analysis and variance analysis of the experimental data,the influence degree of wire diameter(WD)and discharge energy(DE)on the forming quality was determined.Multiple regression analysis was performed using the response surface methodology.A prediction model for the attaching-die state coefficient was established accordingly.The following optimal arrangement of parameters was obtained(WD=0.759 mm,DE=2.926 kJ).The attaching-die state coefficient reached the peak value of 0.001.Better optimized wire diameter and discharge energy for a better attaching-die state could be screened by CCD compared with OED.The response surface method in CCD was more suitable for the design and optimization of the considered process parameters.展开更多
In this work,the magnetic pulse forming process was used to flange the AA 3003-O aluminum alloy tube to improve the flanging formability limit.The results show that there are critical discharge energy values for the f...In this work,the magnetic pulse forming process was used to flange the AA 3003-O aluminum alloy tube to improve the flanging formability limit.The results show that there are critical discharge energy values for the flanging dies with varied slope angle.The mechanism of magnetic pulse flanging process is the bulging in contrast to the expanding of the quasi-static flanging.For the flanging with 90 slope degree,the limited hoop strain at the outer fringe could be up to 0.54 without rapture,to which the limit of simple tension limit is improved by 85%in contrast.The 180 degree flanging at tube end can be achieved by one time magnetic pulse forming.展开更多
文摘The microstructure of the thin-walled tubes with high-strength aluminum alloy determines their final forming quality and performance. This type of tube can be manufactured by multi-pass hot power backward spinning process as it can eliminate casting defects, refine microstructure and improve the plasticity of the tube. To analyze the microstructure distribution characteristics of the tube during the spinning process, a 3D coupled thermo-mechanical FE model coupled with the microstructure evolution model of the process was established under the ABAQUS environment. The microstructure evolution characteristics and laws of the tube for the whole spinning process were analyzed. The results show that the dynamic recrystallization is mainly produced in the spinning deformation zone and root area of the tube. In the first pass, the dynamic recrystallization phenomenon is not obvious in the tube. With the pass increasing, the trend of dynamic recrystallization volume percentage gradually increases and extends from the outer surface of the tube to the inner surface. The fine-grained area shows the states of concentration, dispersion, and re-concentration as the pass number increases. .
基金Projects (50905144, 50875216) supported by the National Natural Science Foundation of ChinaProject (09-10) supported by the State Key Laboratory of Materials Processing and Die & Mould Technology, ChinaProject (JC201028) supported by the Northwestern Polytechnical University Foundation for Fundamental Research, China
文摘Thin-walled aluminum alloy tube numerical control (NC) bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of the parameters was proposed based on the finite element (FE) simulation, and the significance analysis of the processing parameters on the forming quality in terms of the maximum wall thinning ratio and the maximum cross section distortion degree was implemented using the fractional factorial design. The optimum value of the significant parameter, the clearance between the tube and the wiper die, was obtained, and the values of the other parameters, including the friction coefficients and the clearances between the tube and the dies, the mandrel extension length and the boost velocity were estimated. The results are applied to aluminum alloy tube NC bending d50 mm×1 mm×75 mm and d70 mm×1.5 mm×105 mm (initial tube outside diameter D0 × initial tube wall thickness t0 × bending radius R), and qualified tubes are produced.
基金supported by National Natural Science Foundation of China(Grant Nos.51975202(Junjia Cui received the grant)and 52175315(Guangyao Li received the grant)).
文摘Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness.They can be produced at room temperature by the electrohydraulic forming process.In the present study,the influence of the related parameters on the forming quality of a 6063 aluminum alloy sinusoidal corrugation tube has been assessed.In particular,the orthogonal experimental design(OED)and central composite design(CCD)methods have been used.Through the range analysis and variance analysis of the experimental data,the influence degree of wire diameter(WD)and discharge energy(DE)on the forming quality was determined.Multiple regression analysis was performed using the response surface methodology.A prediction model for the attaching-die state coefficient was established accordingly.The following optimal arrangement of parameters was obtained(WD=0.759 mm,DE=2.926 kJ).The attaching-die state coefficient reached the peak value of 0.001.Better optimized wire diameter and discharge energy for a better attaching-die state could be screened by CCD compared with OED.The response surface method in CCD was more suitable for the design and optimization of the considered process parameters.
基金Item Sponsored by National Basic Research Program of China[973 Program][2011CB012805]
文摘In this work,the magnetic pulse forming process was used to flange the AA 3003-O aluminum alloy tube to improve the flanging formability limit.The results show that there are critical discharge energy values for the flanging dies with varied slope angle.The mechanism of magnetic pulse flanging process is the bulging in contrast to the expanding of the quasi-static flanging.For the flanging with 90 slope degree,the limited hoop strain at the outer fringe could be up to 0.54 without rapture,to which the limit of simple tension limit is improved by 85%in contrast.The 180 degree flanging at tube end can be achieved by one time magnetic pulse forming.