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研究了某复杂盒体,零件属于形状复杂、体积分配不均匀且截面不对称的构件。该盒体在直接采用板料进行挤压过程中,材料出现非等速流动而形成缺陷,影响零件的性能;获得的挤压件开口端不平整,材料利用率低。对该铝合金复杂盒体零件进行计算机有限元模拟,详细分析该盒体在挤压过程中出现的缺陷与不足,并提出合适的解决方案,即增加预成形工艺、改进预成形坯的形状。根据计算机有限元模拟的结果,制定合理的成形工艺路线,即下料-预成形-终成形,确定预成形坯的形状。通过实验验证,获得合格的挤压件。针对此类零件可以通过增加成形次数、优化预成形坯形状等方法来克服成形过程中产生的缺陷,提高材料利用率。
A complex box is studied. Parts belong to the components with complex shape, uneven volume distribution and asymmetric section. During the extrusion of the box directly by the sheet material, the material appears non-constant flow and forms defects, which affect the performance of the part; the obtained open end of the extrusion piece is uneven and the material utilization rate is low. The finite element simulation of the complex parts of the aluminum alloy box was carried out. The defects and shortcomings of the box in the extrusion process were analyzed in detail. The suitable solutions were proposed, that is, the preforming process was increased and the preform shape was improved. According to the result of the finite element simulation of the computer, a reasonable forming process route is established, that is, blanking-pre-forming-final forming, and the shape of the preform. Through experimental verification, to obtain qualified extrusion. For such parts can be formed by increasing the number of preforms to optimize the shape and other methods to overcome the defects generated in the forming process and improve material utilization.