[材料成形中的数字化与智能化产品设计]6016铝合金汽车典型结构件固溶成形工艺研究

以某车型铝合金汽车后风挡下横梁为研究对象，利用PAM-STAMP软件进行了一步固溶成形和分步固溶成形工艺分析。通过优化关键工艺参数如摩擦因数和成形温度，结合相应的工艺实验，建立了工艺仿真模型；通过对测量路径上壁厚分布的实验值与数值模拟值进行误差对比分析，判断成形工艺合理性。结果表明：汽车后风挡下横梁采用一次成形方式容易在中间形变突变处造成开裂或减薄现象，随着摩擦因数增大，最小厚度急剧减小；相比一次成形方式，采用分步成形方式，最小减薄率减小了4.67%，回弹量减小了40.21%，温度与摩擦因数对最小厚度的影响较小；经时效处理后进行力学性能检测，铝合金汽车后风挡下横梁抗拉强度达到308 MPa，表明采用固溶成形工艺是可行的。

Research on Solid Solution Forming Processes of Typical Automotive Structural Parts with 6016 Aluminum Alloy

The aluminum alloy car windshield beams were taken as the research objects,and the PAM-STAMP software was used to analyze the one-step solid solution forming and step-by-step solid solution forming processes. By optimizing key processing parameters such as friction coefficient and forming temperature and carrying out the corresponding processing experiments, a processing simulation model was established. The rationalities of the forming processes were judged by using the error analysis between the experimental values and the numerical simulation ones of the wall thickness distributions on the measurement paths. The results show that after the car windshield beams using a forming way to cause cracking or deformation mutation in the middle place thinned phenomenon, along with the friction coefficient increases, the minimum thickness is fallen sharply. Compared with the one-step forming method, the step-by-step forming method is adopted, the minimum thinning rate is reduced by 4.67%, the rebound amount is reduced by 40.21%, and the temperature and friction coefficient have less influences on the minimum thickness. The mechanics property tests after aging treatment, the tensile strength is of 308 MPa, which proves that the aluminum alloy car windshield beams formed by solid solution processes are feasible.