薄壁异形方半管零件充液成形工艺研究

目的 为解决薄壁异形方半管零件成形过程中易起皱、破裂、形状冻结性不佳的难题，引入充液成形工艺。为进一步掌握不同工艺参数对零件成形性能的影响，对薄壁异形方半管零件的充液成形过程进行研究。方法 以液室压力、压边力、拉深深度、摩擦因数等工艺参数为影响因子，进行正交试验，通过分析不同工艺参数下零件最大减薄率、贴模度、最大回弹量的变化规律，掌握充液成形工艺中不同工艺参数对零件起皱、破裂、形状冻结性的影响。结果 零件的破裂和起皱现象受液室压力影响显著，而零件的形状冻结性则受压边力影响较大。在数值模拟中，优化后的最优工艺参数如下:液室压力为15 MPa，压边力为120 kN，拉深深度为110 mm，摩擦因数为0.15。经模拟验证，与优化前相比，在该工艺参数下得到的结果更优，零件最大减薄率降低到11.5%、贴模度提高了0.212 mm、最大回弹量降低了1.955 mm。结论 通过模拟分析和现场试验验证可知，采用正交试验得到的最优工艺参数可以完成半管零件的成形，合理的工艺参数能有效抑制零件起皱、破裂、形状冻结性不佳的现象，从而提高半管零件的成形性能。

Liquid Filling Forming Technology of Thin-walled Irregular Square Half Pipe Parts

In order to solve the problems of wrinkling, cracking, and poor shape freezing during the forming process of thin-walled irregular square half pipe parts, the liquid filling forming technology is introduced. The work aims to study the liquid filling forming technology of thin-walled irregular square half pipe parts, so as to further understand the effect of different process parameters on the forming performance of the parts. Process parameters such as liquid pressure, binder force, drawing depth, and friction coefficient were used as the affecting factors to conduct the orthogonal experiment. By analyzing the changes in the maximum thinning rate, maximum wrinkle height, and maximum rebound deformation of parts under different process parameters, the effect of different process parameters on the wrinkling, fracture, and shape freezing of parts in liquid filling forming technology was clarified. The fracture and wrinkling of parts were significantly affected by the liquid pressure, while the shape freezing was greatly affected by the binder force. In numerical simulation, the optimal process parameters after optimization were:liquid pressure of 15 MPa, binder force of 120 kN, drawing depth of 110 mm, and friction coefficient of 0.15. After simulation verification, the results obtained under the optimal process parameters were the best. Compared to those before optimization, the maximum thinning rate of parts decreased by 11.5%, the maximum wrinkle height increased by 0.212 mm, and the maximum rebound deformation was reduced by 1.955 mm. Through simulation analysis and on-site experimental verification, the optimal process parameters obtained through orthogonal experimental analysis can complete the forming of half pipe parts. Reasonable process parameters can effectively suppress the phenomenon of wrinkling, cracking, and poor shape freezing of parts, thereby improving the forming performance of half pipe parts.