| 摘要: |
| 以5A06铝合金薄壁球形封头为研制对象，针对钣金工艺加工瓶颈和一步气胀成形减薄过大问题，开展预先热拉深-高温气胀成形工艺研究。利用有限元进行数值模拟分析，研究了预成形、气压加载速率对壁厚分布均匀性的影响，确定预成形和终成形优化方案，设计预成形和终成形模具，采用预拉深-高温气胀成形工艺试制5A06铝合金薄壁球形封头。结果表明，增加预成形后，球形封头最大减薄率从48.7%减小到24%，气压加载速度过大或过小对成形均有不利影响。在460～480℃温度下进行试验，加载氩气至1MPa，保压5min，成功制备出了5A06铝合金薄壁球形封头，封头表面质量好，成形精度高，型面与样板间隙小于0.2mm，封头壁厚在1.16～1.52mm之间，符合壁厚不低于1.1mm的要求。 |
| 关键词: 5A06铝合金 薄壁球形封头 高温气胀成形 数值模拟 成形精度 |
| 基金项目: |
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| Research on High Temperature Gas Bulging Forming of Aluminum Alloy 5A06 for Thin Wall Spherical Head |
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Qin Zhonghuan, Xu Bingtong, Li Baoyong, Zhang Shuke, Li Xin, Ye Zhixiong
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1. Beijing Hangxing Techology Development Co., Ltd., Beijing 100013
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| Abstract: |
| Taking 5A06 aluminum alloy thin wall spherical head as the research object, aiming at the bottleneck of the sheet metal processing and the problem of over-slimming in one-step gas bulging forming, the pre-heat drawing-high temperature gas bulging forming process was studied. The finite element method was used for numerical simulation analysis to study the effect of preforming and pressure loading rate on the uniformity of wall thickness distribution. By determining the optimal solution for preforming and final forming and designing preforming and final forming dies, the 5A06 aluminum alloy thin wall spherical heads were trial-manufactured by pre-heat drawing-high temperature gas bulging forming process. The results show that the maximum thinning rate of the spherical head decreases from 48.7% to 24% after the preforming is applied, and too large or too small air pressure loading speed has an adverse effect on the forming. The 5A06 aluminum alloy thin wall spherical head was successfully prepared at temperature of 460～480℃. Argon gas was loaded to 1MPa and maintained for 5 minutes. The surface quality of the head is good and the forming accuracy is high. The gap between the surface and the template is less than 0.2mm. The wall thickness of the head is between 1.16mm and 1.52mm, which meets the requirement of a wall thickness of not less than 1.1mm. |
| Key words: 5A06 aluminum alloy thin wall spherical head high temperature gas bulging forming numerical simulation forming accuracy |
