摘要
目的解决室温条件下因铝合金塑性流动不均而导致的零件开裂和尺寸偏差等问题。方法利用高速冲击提高材料成形极限以及流体均匀载荷精确控形的优势,提出了电磁冲击液压工艺并实现了铝合金阵列结构零件的成形,采用实验手段研究了放电电压和放电次数对零件贴模精度和厚度分布的影响。结果随着放电电压的增大,零件的成形深度增大。在单次放电8kV下,板料最大成形深度达到模具深度的97%,连续3次放电8kV后,零件通道填充率达到89.7%。建立了与物理实验模型一致的电磁-流体-结构的多物理场耦合仿真模型,发现冲击液体对板料施加的瞬态压强超过200MPa,板料最大变形速度达到40.5m/s。模拟得到的板料变形轮廓与实验结果一致,证明了多物理场耦合仿真模型的准确性。结论电磁冲击液压成形是一种新型的高速成形方法,能够实现铝合金阵列微结构零件的精确制造,为提高复杂薄壁难变形构件的成形性能和精度提供了新的技术手段。
The work aims to solve the problems such as cracks and dimensional deviations caused by uneven plastic flow of aluminum alloy material at room temperature.Using the advantages of high speed impact to improve the forming limit of mate-rials and precise shape control of uniform fluid load,an electromagnetic impact hydraulic technology was put forward and the forming of aluminum alloy array structure parts was realized.The effects of discharge voltage and discharge times on the accu-racy and thickness distribution of the parts were studied through experiments.With the increase of discharge voltage,the form-ing depth of the part increased.Under discharge voltage of 8 kV,the maximum forming depth of sheet reached 97%of the die depth,and the filling rate of parts channel reached 89.7%after three consecutive discharges of 8 kV.A multi-physical coupling simulation model of electromagnetic-fluid-structure was established,which was consistent with the physical experiment model.It was found that the transient pressure exerted by the impact liquid on the plate exceeded 200 MPa,and the maximum sheet de-formation velocity reached 40.5 m/s.The deformation profile of sheet obtained by simulation was consistent with the experi-mental results,which proved the accuracy of the multi-physics coupling simulation model.Electromagnetic impact hydraulic forming is a new high-speed forming method,which can realize the precise manufacturing of aluminum alloy array mi-cro-structure parts,and provide a new technical means to improve the formability and accuracy of complex thin-wall refractory components.
作者
颜子钦
赵鹏
朱玉德
阳光
王瀚鹏
徐勇
崔晓辉
YAN Ziqin;ZHAO Peng;ZHU Yude;YANG Guang;WANG Hanpeng;XU Yong;CUI Xiaohui(College of Mechanical and Electrical Engineering,Central South University,Changsha 410083,China;Light Alloy research Institute,Central South University,Changsha 410083,China;EMPuls Technology Co.,Ltd.,Hubei Xiangyang 441021,China;Institute of Metal Research,Chinese Academy of Sciences,Shenyang 110016,China)
出处
《精密成形工程》
北大核心
2024年第3期123-130,共8页
Journal of Netshape Forming Engineering
基金
国家自然科学基金(52275394)
中南大学高性能复杂制造国家重点实验室项目(ZZYJKT2020-02)。
关键词
电磁冲击液压
阵列微结构
高速率成形
多物理场耦合仿真
流固耦合
electromagnetic impact hydraulic forming
micro array-structure
high speed impact forming
multi-physics coupling simulation
fluid-structure interaction
作者简介
通信作者:崔晓辉。
