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针对薄壁板材零件小圆角特征成形制造难的问题,提出了一种新型胀压复合成形工艺.其关键工艺参数为:预成形高度、预成形凹圆角大小和终成形胀形压力与背压凸模运行速度匹配关系.预成形高度决定了终成形小圆角的材料储备,预成形凹圆角的最佳值为充液拉深时凸模圆角可取的最小值,通过理论分析给出了预成形高度和预成形凹圆角的计算方法.建立了胀压复合成形过程力学模型,通过应力状态分析给出了不同胀形压力与背压凸模运行速度匹配关系下坯料圆角区变形状况.同时基于有限元模拟和工艺试验,研究了预成形高度和终成形胀形压力与背压匹配路径对试验件成形质量的影响,验证了理论分析的准确性,并证明了该新工艺的适用性.
Aiming at the problem of forming small fillet features of thin-walled sheet metal parts, a new type of compounding process of bulging and pressing is proposed, the key process parameters are as follows: pre-forming height, pre-forming concave fillet size and final forming bulging pressure and Back pressure punch running speed matching relationship.Preform height determines the final forming small fillet material reserves, the best value of the preforming concave fillet is the minimum value of the fillet fillet of the punch filling, The calculation method of the preforming height and the preformed concave fillet is given.The mechanical model of the compounding process is established and the billet shape of the billet Corner zone deformation situation.At the same time based on the finite element simulation and the technology experiment, the influence of the preforming height, the final forming bulging pressure and the back pressure matching path on the forming quality of the test piece was studied, the accuracy of the theoretical analysis was verified, The applicability of this new process.