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铝合金矩形截面内高压成形圆角充填行为研究

期刊名称：机械工程学报
时间：2010.6.6
页码：59-64
分类：TG394[金属学及工艺—金属压力加工]
作者机构：[1]哈尔滨工业大学材料科学与工程学院,哈尔滨150001
相关基金：国家杰出青年科学基金资助项目（50525516）
相关项目：极小曲率半径管充液剪切弯曲的成形机理研究

关键词：内高压成形, 铝合金, 矩形截面, 圆角充填, 润滑, Hydroforming Aluminum alloys Rectangular cross sections Transition corner filling Lubrication

中文摘要：

为了研究铝合金矩形截面内高压成形过程圆角充填行为,设计制造了专用试验装置,测试充填过程中圆角半径与内压的定量关系及其润滑条件影响,分析直边区与圆角区的过渡处开裂的机理,并对内压理论计算值与试验值进行对比。结果表明：充填过程中随圆角半径的减小,所需内压逐渐增大。当相对圆角半径大于5时,圆角半径变化趋势较快;而当相对圆角半径小于5时,变化趋势逐渐平缓。润滑条件对圆角充填影响较大,润滑的改善使成形相同圆角所需内压降低,极限圆角半径减小。从截面直边区的中点到直边区与圆角区的过渡点等效应力逐渐增大,所以过渡点附近最易发生壁厚过度减薄甚至开裂。对于硬化材料,未考虑材料硬化的内压理论计算值明显小于试验值,内压理论计算时必须使用材料硬化后的流动应力。

英文摘要：

To study the filling behavior of transition corner of an aluminum alloy rectangular section tube in hydroforming process,a special test device is designed and manufactured.The quantitative relationship between the corner radius and internal pressure as well as the influence of lubrication condition on transition corner filling are tested,the mechanism of cracking at the transition point between straight side area and corner area is analyzed,and a comparison is made between the theoretical value of internal pressure and the tested value.The results show that the internal pressure needed in the process of filling increases along with the decrease of corner radius of the tube.When the relative corner radius is larger than 5,the change of corner radius tends to be fast;when the relative corner radius is smaller than 5,the change tends to be slow.Lubrication condition has significant influence on transition corner filling.Improving lubrication can reduce the internal pressure needed for forming the same corner and decrease the limiting corner radius.From the midpoint of a straight side to the transition point,the effective stress increases gradually.Therefore,excessive thinning of wall or even cracking is easier to occur at the transition region.For the strain-hardening materials,the theoretical value of internal pressure without considering the strain-hardening effect is significantly less than the experimental result,so the strain-hardening effect should be considered.

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