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机械工程学报

机械工程学报 ›› 2019, Vol. 55 ›› Issue (20): 152-159.doi: 10.3901/JME.2019.20.152

• 材料科学与工程 • 上一篇    下一篇

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铝型材多点三维拉压复合弯曲成形工艺

高嵩1, 于长春1, 梁继才2, 李奇涵1, 郝兆朋1, 刘小勇1, 赵希禄3   

  1. 1. 长春工业大学机电工程学院 长春 130012;
    2. 吉林大学材料科学与工程学院 长春 130022;
    3. 埼玉工业大学机械工学科 深谷 369-0293 日本
  • 收稿日期:2019-01-01 修回日期:2019-06-24 出版日期:2019-10-20 发布日期:2020-01-07
  • 通讯作者: 梁继才(通信作者),男,1962年出生,博士,教授,博士研究生导师。主要研究方向为金属型材柔性先进弯曲成形技术。E-mail:ltazh@qq.com
  • 作者简介:高嵩,男,1987年出生,博士,讲师,硕士研究生导师。主要研究方向为金属型材柔性先进弯曲成形技术。E-mail:gaosong@ccut.edu.cn
  • 基金资助:
    国家自然科学基金（51805045，51675225）、吉林省教育厅"十三五"科学技术（JJKH20181032KJ）和教育部"春晖计划"合作科研资助项目。

Multi-points 3D Stretch-press Bending Technology for Aluminum Profile

GAO Song1, YU Changchun1, LIANG Jicai2, LI Qihan1, HAO Zhaopeng1, LIU Xiaoyong1, ZHAO Xilu3   

  1. 1. School of Mechatronic Engineering, Changchun University of Technology, Changchun 130012;
    2. Colloge of Material Science and Engineering, Jilin University, Changchun 130022;
    3. College of Mechanical Engineering, Saitama Institute of Technology, Fukaya 369-0293, Japan
  • Received:2019-01-01 Revised:2019-06-24 Online:2019-10-20 Published:2020-01-07

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摘要： 轻量化薄壁型材三维弯曲结构件是高端装备制造业中一种难成形加工的关键零部件。针对此类制件的高精度、低成本的成形需求，提出一种拉弯-压弯相结合的铝合金型材三维弯曲成形工艺，设计多点联动的拉压复合成形单元体结构，通过水平方向由夹钳带动拉弯，垂直方向由各单元体上液压执行机构压弯，实现"W"形三维弯曲零件的成形，并研制成形装备样机。建立分析成形过程及回弹预测的数值仿真模型，通过试验对模型的有效性进行验证，仿真结果与试验结果回弹变形一致，回弹预测最大误差小于15%。此外，研究拉力对矩形截面型材拉压复合成形件回弹变形的影响规律，预拉伸力较补拉伸力对成形件的回弹减小趋势更为明显，当预拉伸力从零达到临界塑性应力Aσs时，总回弹减少了26.81%，为保证成形件不发生截面畸变和破裂等成形缺陷，确定了预拉伸力为Aσs、补拉伸力为0.3Aσs的最优工艺参数。所提出的多点三维拉压复合弯曲成形工艺解决了W形一类型材传统三维拉弯无法实现的多向曲率半径复杂弯曲成形的技术难题，为实现镜面对称结构件的成对一次成形提供了一种新方法。

关键词: 多点成形, 三维拉弯, 回弹预测, 预拉伸力, 补拉伸力

Abstract: The lightweight thin-walled three-dimensional (3D) curved structure parts are key components in the high-end equipment manufacturing industry, which are difficult to form and process. In order to satisfy the requirements of complex bending and low cost forming, a new type of multi-points 3D stretch-press bending technology for aluminum profile is proposed. The structure of multi-point linked flexible fundamental unit(FFU) for stretch-press bending process is designed. The clamp is used to drive the workpiece to close with the multi-points die (MPD) in the horizontal direction. Once the clamps reach the target position, the hydraulic piston rod of each FFU presses down to shape the workpiece in the vertical direction. According to the forming principle of this new process, a prototype of forming equipment is developed, which realizes the forming of the W-shpae part. Then a numerical simulation model is established to analysis the forming procedure and to predict springback. The forming experiments are conducted to verify the simulation model. It can be seen that the simulation results are in good agreement with the experimental results. The maximum prediction error is less than 15%. In addition, the effect of tensile force on springback deformation in this process is studied. When the pre-stretch force reaches the critical plastic stress Aσs from zero, the total springback decreases by 26.81%. The conclusion can been drawn that the pre-stretch force has more obvious effect on springback reduction than post-stretch force. In order to ensure that the forming parts do not have forming defects such as section distortion and fracture, the springback are 6.13 mm and 4.11 mm in the horizontal and vertical directions with the optimum process parameters pre-stretch force Aσs and the post-stretch force 0.3 Aσs in forming of a W-shape target part. The multi-points 3D stretch-press bending process is proposed to realize complex bending of multi-direction radius of curvature, such as the W-shape part. A new method is provided to achieve the pairwise forming of the mirror symmetrical structural parts which will be applied in high-end equipment manufacturing industry.

Key words: multi-point forming, 3D stretch-bending, springback prediction, pre-stretch force, post-stretch force

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