预胀对铝合金充液拉深影响的数值模拟分析-numerical simulation and analysis of the effect of pre-expansion on liquid-filled drawing of aluminum alloy.docxVIP

预胀对铝合金充液拉深影响的数值模拟研究摘要目前，汽车轻量化对节约能源，减少环境污染等方面越来越受到关注， 那么铝合金汽车零部件也就越来越被广泛的应用，但铝合金板材比钢板的成 形性低很多，而且汽车覆盖件的形状复杂，用传统的冷冲压成形工艺很容易 出现褶皱和拉裂等质量缺陷。板材充液拉深成形是传统冲压成型工艺和液压成形工艺的结合，在成形 过程中，凸模接触板料，在液室压力的作用使板料成形。板料液压拉深成形 比传统的拉深工艺具备更多的优点，比如可获得更高的拉深比，更好的表面 质量和较高的尺寸精度。预胀是充液拉深成形过程之前液室预先增加压力， 使板料预先胀形形成软拉延筋的成形方式。软拉延筋的形成可增加板料成形 的稳定性和获得更好零件质量。本文以铝合金异形底盒形件和汽车油底盒为研究对象，针对它们的零件 形状进行成形工艺分析，采用预胀成形与充液拉深成形工艺相结合的新工艺 进行零件的成形，并应用有限元模拟软件 Dynaform5.7.1 对铝合金异形底盒 形件与汽车油底盒进行有限元模拟。对铝合金异形底盒形件和汽车油底盒成形结果进行分析，总结预胀压 力、预胀高度、液室压力和压边间隙等参数对零件成形的影响规律。由于汽 车油底盒形状复杂，板料成形时应力应变分布极为复杂，传统的汽车油底盒 都需要两次以上的拉深成形，而本文对汽车油底盒进行了一次冲压成形的可 行性研究，得出以下结论：在零件成形过程中，合适的预胀压力和预胀高度 对零部件形成初始软拉延筋及零件最终成形质量有很大的提高；合理的液室 压力加载曲线，得到的零件表面质量较好和壁厚分布均匀；合适的压边间隙 可以获得成形效果较好和壁厚分布均匀的零件；适当的增加凸模与板料的摩 擦系数和选择合适的凹模圆角半径可以获得成形质量较好的零件。最后得到了合理的工艺路径，由此获得了合格的铝合金异形底盒形件和 汽车车油底盒。关键词 充液拉深；预胀；数值模拟；盒形件Research on the Aluminum Alloy by Hydrodynamic Deep Drawing Adopting pre-bulging Based on Numerical SimulationAbstractAt present, the automotive light weighting to save energy, reduce environmental pollution is more and more attention. Aluminum alloy is used in making auto parts comprehensive. Aluminum alloy blank is more difficult form than steel blank. The traditional stamping form can result in winkle and damage because the shape of auto panel is more complicated.Hydraumatic draw form is the combination of the traditional stamping form and Hydraumatic form. In the form process, the liquid press makes the blank form. Hydraumatic draw form has more advantage than the traditional stamping form, such as getting more high draw ratio, and stress strain, better surface quality and measurement accuracy. Pre-bulging is that add liquid home press before Hydraumatic draw form, and get soft draw bead; which can improve the stability and part surface quality.This paper is regard especial box part and auto oil box as research object, combining pre-bulging form and hydraumatic draw form to analysis the form of especial box and auto oil box by dynaform5.7.1.The paper analyzes the form results fo