板液压成形及无模充液拉深技术

板液压成形技术是液压成形技术中重要的一类 ,广泛地应用于宇航、汽车等工业领域。近年来由于新材料和复杂几何形状零件的不断出现 ,更加突出此种技术的关键性。本文就板液压成形技术原理、数值模拟技术和分类进行了研究 ,探讨了此种技术将来的发展 ,介绍了基于板液压成形技术的无模充液拉深技术 ,利用实验和数值模拟技术对此技术进行了分析 ,验证了此项技术的可行性 ,并取得了较好的结果     

材料性能参数对液压成形件厚度分布的影响规律研究

厚度分布均匀性是管件液压成形质量的重要评价指标。文章提出了厚度分布均匀性评价指标函数,建立了空心阶梯轴零件的有限元模型,并通过实验验证了仿真结果的有效性。通过模拟研究了材料的应变强化系数K、加工硬化指数n和厚向异性指数R对液压成形管件厚度分布均匀性的影响规律。     

Process layout avoiding reverse drawing wrinkles in hydroforming of sheet metal

Sheet metal forming processes like the fluid form process or hydromechanical deep drawing have the potential for the manufacture of parts having high precision, large drawing ratio, and low costs especially for small and medium lot sizes. In deep drawing using a separating membrane between the liquid and the sheet the process layout for drawing of complex parts must avoid not only the typical failures of bottom fracture, first and second order wrinkles, but also an additional type of wrinkles which are maybe created at the beginning of the process. The development of these wrinkles is described using an analytical model, which was validated by experimental results. The model was used to develop the process layout for deep drawing of a complex sheet metal part.     

基于Dynaform的三通管件液压成形影响因素分析

通过采用Dynaform软件对三通管件液压成形过程进行模拟仿真,确定了影响其成形质量的因素,得到了各参数对管件成形的影响规律,通过控制各参数可有效地提高三通管件液压成形的质量,提高生产效率。     

汽车副架液压胀形预成形工艺设计的数值模拟

对汽车副架液压胀形预成形工艺设计进行了数值模拟研究。应用建立在刚塑性有限元法 (FEM)基础上的HydroFORM 3D软件与Oyane延性断裂准则相结合的数值模拟方法 ,重点针对管料初始尺寸的确定 ,给出了汽车副架液压胀形预成形工艺的数值模拟结果。分析表明 ,确定适合预成形工艺条件的管材初始尺寸有利于汽车副架液压胀形工艺的实施     

锥盒形件液压成形的实验研究

液压成形的关键技术是控制压边力和液池压力的加载曲线 ,本文通过实验研究 ,获得了锥盒形件液压成形的压边力和液池压力的加载曲线 ,指出了该类零件液压成形的失效形式 ,并对产生失效的原因进行了深入分析 ,为应用液压成形技术生产具有该形状特征的汽车覆盖件提供了技术依据     

Hydroforming process optimization of aluminum alloy tube using intelligent control technique

In this study, to determine the optimal loading path of tube hydroforming process, a database-assisted fuzzy process control algorithm proposed previously by the authors was applied to T-branch forming with a counterpunch. The tubular material used is aluminum alloy (A6063-T1) and has an outer diameter of 42.7 mm and wall thickness of 1.2 mm. Control variables is axial feed, counterpunch displacement, and internal pressure. The first two variables are dependent on the last one, which is an independent variable. In the control algorithm, new evaluation functions are adopted for buckling at the shoulder part of the branch and for contact fitting with a counterpunch. For a “virtual control system” including fuzzy algorithm with the evaluation functions, an explicit dynamic finite element code is used in the simulation. The experiments are carried out using a fuzzy controlled path obtained by the virtual control system, compared with the conventional manual control path that is attained by a trial-and-error approach. As a result, a T-branch product is successfully hydroformed. This result shows that the fuzzy control algorithm and virtual control system can provide an adequate loading path in the hydroforming process for an aluminum alloy tube.     

Material Flow Control and Optimization in High‐Pressure Sheet Metal Forming by Active‐Elastic Tools

High‐pressure forming of metal sheets is an innovative forming technology for the production of complex components and offers high potentials to improve the properties and qualities of sheet metal parts. This report describes investigations of a newly developed active‐elastic tool system referred to as ACTEC system. Unlike the use of a comparable semi‐rigid tool system, the ACTEC system shows improvements with respect to the material flow in the flange area and reduced sheet thinning in critical corner regions of the workpiece. In addition, the clamping forces respectively sealing forces necessary to avoid leakage in the tool system during the forming process can be reduced. Moreover, the specific design of the ACTEC‐system as well as current experimental examinations are presented and discussed.     

三台阶轴内高压成形中轴向补料的有限元分析

为研究内高压成形台阶轴过程中轴向补料参数对工艺的影响,利用大变形非线性塑性有限元方法对内高压成形三台阶轴工艺进行了分析,讨论了补料量在理论值的80%～120%变化时零件的壁厚及应变分布规律,并就其成因进行了讨论.研究表明,补料量低于理论值的90%及高于理论值的110%是轴向补料参数选取的危险区间,容易引起折叠或破裂失稳,按照理论计算值进行轴向补料,壁厚及应变分布最为理想.     

充液成形设备双闭环控制分析

目的 研究先进充液成形设备的精度控制技术,以满足充液成形过程中对成形介质压力及侧推油缸位置的高精度控制要求,并确保模具型腔的密封性和零件成形的稳定性。方法 基于PLC控制器下的PID闭环控制功能,将速度闭环和位置或压力闭环进行集成,开发应用于液压系统的双闭环控制方法。结果 使用双闭环控制方法,可以调整侧推油缸的位置控制精度及响应速度,并将精度控制在0.1 mm以内,也可调整增压装置的输出端压力控制精度,使精度达到0.3 MPa。结论 在利用充液成形设备进行液压成形的过程中,双闭环技术可以实现设备侧向密封的精确位置控制以及型腔内压力的精确控制。