5052铝合金板材磁脉冲动态拉伸塑性失稳分析

为揭示磁脉冲成形的增塑机制,采用理论分析与微观组织观察相结合的方法对5052铝合金板材磁脉冲动态拉伸过程中动态成形行为和塑性失稳机制进行了系统研究.结果表明,惯性力在动态成形中起主要作用,惯性力对试样的结构失稳具有抑制作用,从而使试样的塑性提高并产生分散失稳;5052铝合金动态成形和准静态成形的成形性质相似,不会产生特殊的组织结构,塑性变形机制均为位错滑移机制;准静态成形过程以均匀单系位错滑移为主,断裂伴随着位错的缠结和攀移;而动态成形过程中,位错滑移趋于多系开动,在大面积区域出现明显的交滑移现象,且滑移带较准静态成形时窄且密,位错组态更均匀;动态成形的多系滑移和位错均化作用可在比准静态成形高的多的塑性应变水平下形成,从而使材料表现出较高的塑性和强度.     

花键管成形的力学分析

花键管挤压成形中挤压力的计算、失稳弯曲分析、摩擦及润滑方式的选择对分析挤压成形的可行性和花键成形过程分析很重要。本文通过对花键筒的成形方式选择和成形过程分析得出对不规则截面管件挤压变形过程中力的分析和计算方法。     

铝合金筒形件磁脉冲辅助冲压成形试验研究

针对铝合金筒形件传统拉深成形中由于成形性差容易出现拉裂问题,采用拉深预成形和磁脉冲辅助成形相结合的方法对5052-O铝合金板材进行筒形件成形性试验研究,探索磁脉冲辅助冲压成形工艺提高材料成形性的可能性。并研究应用磁脉冲成形减小预成形筒形件圆角半径的工艺可行性。结果表明:与普通冲压相比,磁脉冲辅助冲压成形能够提高材料的成形性,且提高放电电压和增加放电次数能增强圆角的再变形能力,圆角变形更加均匀。普通拉深筒形件减薄最严重部位出现在筒壁和圆角相接处,而磁脉冲辅助冲压成形筒形件有两个减薄严重部位:侧壁与圆角相接处和筒底与圆角相接处。     

异种金属磁脉冲连接技术的研究与应用

磁脉冲连接是基于磁脉冲成形技术发展起来的一种固态连接技术,可实现难以获得熔化焊接头的异种金属材料的冶金连接.本文从磁脉冲连接技术的原理和特点出发,重点综述了异种金属材料磁脉冲连接接头强度及微观组织、工艺应用及设备的国内外现状,阐明了深入开展磁脉冲连接技术研究的重要意义.     

筒形件磁脉冲辅助冲压成形数值模拟

针对磁脉冲辅助冲压成形过程,提出了基于ANSYS平台的有限元分析程式,通过编制用户子程序,采用重启动分析法,建立了冲压预成形过程显式求解和瞬态磁脉冲成形"松散"耦合分析之间的动态连接,并用于5052-O铝合金圆筒形拉深件磁脉冲辅助冲压成形过程的有限元仿真研究。结果表明,所建立的有限元分析方案,能实现圆筒形件磁脉冲辅助冲压成形连续变形过程的模拟,板坯变形信息体现了准静态冲压变形和高速率磁脉冲成形之间的耦合。有限元模拟结果与实验吻合较好。     

5A02铝合金管件磁脉冲冲击弹性介质成形试验

提出管件磁脉冲冲击弹性介质成形技术,研究了放电能量、成形温度、复合成形等对5A02铝合金管件成形的影响规律.室温下,管件的变形程度随着放电能量的增加而增加(放电能量为7 kJ时,膨胀率为24％,壁厚减薄率为22％),并且最大变形位置随着放电能量的增加逐渐向中心靠近(放电能量为7 kJ时,最大变形位置位于中心区域).当放...     

磁脉冲冲孔试验研究

磁脉冲冲孔是一种高能率成形方式,特别适合于薄板加工.采用试验的方法,在3种不同成形方式下,研究放电电压对冲孔成形性能的影响.研究结果表明：冲孔所需最小成形电压随着板料厚度的增加而增加;对于同一厚度的铝板,当电压大于最小冲孔电压时,电压越大,断面质量越好;在3种成形方式中,板坯上下放置弹性传压介质的成形方式毛刺区域最小,断面质量最佳,但所需能量最大.     

多缝隙集磁器的磁脉冲管件缩径成形及连接

磁脉冲管件缩径是金属管件与金属或者非金属管件、杆件连接时使用的一种高速成形工艺.集磁器能显著提高磁脉冲的焊接效率.传统集磁器中通常存在一个缝隙,用于改变感应电流流向,进而调控磁力分布.缝隙的存在使得电磁力在周向上分布不均,靠近缝隙处的区域难以焊接,这种缺陷降低了磁脉冲管件缩径的周向均匀性.为了提高磁脉冲管件缩径的均匀性...     

内套管失稳成形工艺及模具设计

介绍了一种利用直杆在一定压力下失稳的特性来成形的方法 ,并对其工艺流程、模具原理和模具结构进行了分析     

管材内液塑性成形中的拉伸失稳分析

针对目前管材内液塑性成形中缺陷对工艺的影响,借助塑性力学分析手段,对轴向和环向的应力比对拉伸失稳极限应变的影响进行了分析。研究表明,胀形过程中,管坯的全部外载荷都是通过内部液压生成;内高压成形过程中,随应变比绝对值的增加,等效应变、环向应变及轴向应变呈指数增长趋势,而厚向应变对应力比的变化不敏感,其中集中性失稳应变量大约是分散性失稳的两倍,且随应变比绝对值的增加,集中性失稳的应变极限增加速度大于分散性失稳,破裂倾向降低明显。     

Effects of process parameters on warm and electromagnetic hybrid forming of magnesium alloy sheets

As the lightest structural metal, magnesium (Mg) is attracting increasing interest from both the industrial and academic fields. Magnesium alloy parts are mainly processed by die casting due to their poor sheet formability at room temperature. Warm forming is a popular method of forming; Mg alloy sheets produced in this manner show excellent formability around 200-400 °C. Electromagnetic forming (EMF) can improve the formability of metal sheets without the need for lubricants. In this paper, a new approach, called warm and electromagnetic hybrid forming (WEMF), is presented. The effects of voltage, capacity, and temperature on the bulging height of Mg alloy sheets are investigated. Results show that the bulging height of Mg sheets increases with moderate discharging energies. Enhancing the discharging voltage is also a more efficient method for increasing bulging height compared to simply increasing the capacity. When the discharging energy is kept constant, the bulging height first decreases (<150 °C) and then increases (>150 °C) from room temperature to 230 °C. The formability of Mg alloy sheets improves with increasing temperature, while the forming efficiency of WEMF decreases under similar conditions.     

电磁平板自由胀形3D数值模拟(英文)

电磁成形是一种高速率成形方法,它能够有效提高金属板材的成形极限。但是电磁成形过程复杂,涉及到磁场?结构场之间的耦合分析。数值模拟提供一种手段去解决耦合问题。然而,大多数的数值模拟都限于2D。建立3D有限元模型去分析电磁平板胀形。成形过程中考虑了板料与底模的接触和板料变形对磁场的影响。板料中心节点和半径20mm处节点的位移随着时间的变化与实验结果一致。分析了塑性应变能和塑性应变。     

拉形动态摩擦系数的正交试验分析

用正交设计法对拉形时的摩擦系数进行了测定,方差分析结果表明,平整量越大摩擦系数越小;润滑剂对摩擦系数的影响最大;摩擦系数随凸模行程的增大而增大,且基本为线性关系。凸模圆角半径处的摩擦系数比凹模圆角半径处的摩擦系数普遍大,这是由凸模圆角半径处的板材变形程度大、板材表面粗糙化大所引起。     

低碳钢多层板点焊动态过程测试与分析

在电阻点焊生产过程中,时常会遇到不同层数的搭接点焊接头.由于多层板接头在实际点焊过程的焊材厚度发生了明显的变化,使得焊机二次回路中的阻抗大幅度波动.因而焊接热量也必然产生显著波动.若不能及时有效地实时调节焊接热量,熔核质量无法保证.通过对焊接热过程的动态测试与分析,探讨了3种不同机制监控方法对低碳钢多层数点焊的适应性,为生产企业选择准确的监控模式和进行有效的质量控制提供了科学依据.     

影响电磁成形质量因素的实验分析

通过对盒形件和艺术件的电磁成形实验，分析了线圈、电压、材料、气流等因素对成形质量的影响，从而得出了获得质量良好的成形件所需注意的几个问题。     

A new joining by forming process to produce lap joints in metal sheets

This paper proposes a new joining by forming process to produce lap joints in metal sheets. The process combines partial cutting and bending with mechanical interlocking by sheet-bulk compression of tabs in the direction perpendicular to thickness. The lap joints are flat with all the plastically deforming material contained within the thickness of the two sheets partially placed over one another. The design of the lap joints is performed by a simple analytical model and the overall concept is validated by means of numerical modelling and experimentation. Destructive shear tests demonstrate the effectiveness and performance of the new proposed lap joints.     

Agile manufacturing of a micro-embossed case by a two-step electromagnetic forming process

A very agile method, that relies solely on simple single-sided tooling, to form open-box-like enclosures with surface detail such as highly embossed surface features is demonstrated and analyzed. For example, this method may be used to fabricate personal electronics cases. The technique uses electromagnetic forces in a two-step process. In the first step a newly developed uniform pressure electromagnetic actuator is used to make a micro-embossed pre-form that can contain very fine surface detail in the part by micro-embossing features in the forming die. This blank is then trimmed. In the second major step electromagnetic flanging is used to give greater depth and steeper walls to the case. Both electromagnetic operations use one-sided tooling and very light equipment. In principle the tooling needed for this type of process can be put to use within days or hours of finalizing the component design and precise tooling tolerances or precise alignment are not required. This work shows the essential feasibility of this approach to manufacturing either small or large lots of components.     

The strain path and forming limit analysis of the lubricated sheet metal forming process

Few previous attempts have been made to analyze numerically the strain path and the forming limit in complex lubricated sheet metal forming. Since usual approaches of solving the lubrication model are limited to axisymmetric and plane strain cases only, this paper developed a unified procedure for combining the finite element code of sheet metal forming, the current lubrication/friction model and forming limit theory, to predict the strain path and fracture strains for either a steady or an unsteady three-dimensional process including both axisymmetric and plane strain cases. The availability of the method must be proved by a published problem, and an axisymmetric stretch forming process was therefore adopted as a benchmark. Numerical results showed that the present analysis provides good agreement with the experimental data of the strain path and the fracture strain for various tribological parameters such as lubricant viscosity and composite roughness of tooling and workpiece, and the advantage of the developed model is that it can be applied to solve the complicated 3D geometric problems.     

电磁力体积力效应对AA5052板材动态成形性的影响

为揭示板材磁脉冲成形的增塑机制,通过设计有/无驱动片作用下的磁脉冲成形工艺方案,对比体积力和面力加载条件下的AA5052板材的平面应变成形极限问题,研究了电磁力体积力效应对材料动态成形性的影响。结果表明,板坯磁脉冲动态成形时,脉冲电磁力体积力的作用形式有助于分散变形,提高板坯的整体塑性水平。随着变形速率的增加,体积力的作用效果更加显著,板坯极限变形能力提高。     

电磁成形中的测量

本文简要介绍了电磁成形中放电电流、管坯与线圈间隙中的磁场测量 ,以及管坯动态变形过程测量的各种方法。通过各种方法的比较分析 ,得出分流器法测放电电流、探测线圈法测感生磁场是切实可行的方法。金属坯料在电磁力作用下的变形过程可用撞针法和高速摄影的办法进行测量 ,每种方法各有其优势和适用范围 ,测量时 ,根据实际情况进行选用。