Analysis of a bulging-pressing compound-forming process for the sheet metal part with a small round corner feature
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摘要: 針對薄壁板材零件小圓角特征成形制造難的問題,提出了一種新型脹壓復合成形工藝.其關鍵工藝參數為:預成形高度、預成形凹圓角大小和終成形脹形壓力與背壓凸模運行速度匹配關系.預成形高度決定了終成形小圓角的材料儲備,預成形凹圓角的最佳值為充液拉深時凸模圓角可取的最小值,通過理論分析給出了預成形高度和預成形凹圓角的計算方法.建立了脹壓復合成形過程力學模型,通過應力狀態分析給出了不同脹形壓力與背壓凸模運行速度匹配關系下坯料圓角區變形狀況.同時基于有限元模擬和工藝試驗,研究了預成形高度和終成形脹形壓力與背壓匹配路徑對試驗件成形質量的影響,驗證了理論分析的準確性,并證明了該新工藝的適用性.Abstract: This study presented a new bulging-pressing compound-forming process to solve the manufacturing problem of a thinwall specimen with a small round corner radius. Its key process parameters were the pre-forming depth, pre-forming concave round corner, and matching relation between the liquid bulging pressure and the backpressure punch velocity in the final forming process. The pre-forming depth determines the material reserves of the small round corner area in final forming. The best pre-forming concave round corner is the minimum punch corner in hydro-mechanical deep drawing. The calculating methods for the pre-forming depth and the pre-forming concave round corner were provided by a theoretical analysis. The mechanical model of the bulging-pressing compound forming process was built. Moreover, the deformation situation in the round corner area with different matching relations between the liquid bulging pressure and the backpressure punch velocity was provided by the stress state analysis. Meanwhile, the influences of the pre-forming depth and the matching relation between the liquid bulging pressure and the backpressure in final forming on the quality of the part were researched based on the finite element simulations and experiments. The accuracy of the theoretical analysis was verified. In addition, the applicability of the new process was proven.
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參考文獻
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