金属薄板杯形件拉深制耳定量预测理论模型

doi:10.3901/JME.2025.04.096

摘要/Abstract

摘要： 因材料面内各向异性，杯形件拉深时会出现波浪状制耳缺陷。为了准确预测制耳，针对现有理论模型仅考虑单向压缩变形的局限性，在考虑微体的双向应力状态和径向不均匀变形影响的基础上，提出一种新的杯形件制耳特征(包括制耳数量、位置、杯壁高度)定量预测理论模型。通过2219-O铝合金杯形件的拉深仿真和试验验证理论模型的准确性。结果表明，制耳个数与面内各向异性系数的极大值个数相同，杯壁高度与各向异性系数r_θ+90呈单调递增关系，杯壁高度的极大值、极小值位置与i>r_θ+90的极大值、极小值位置对应，极大值位置对应出现制耳波峰，极小值位置对应出现制耳波谷。对比不同初始板坯直径下的制耳特征，理论预测的制耳数量与试验完全相同；制耳波谷位置完全相同，制耳波峰位置略有误差，最大误差不超过4°；杯高和制耳高度的预测精度显著优于现有理论模型预测精度，且预测精度对于不同的初始板坯直径具有更好的一致性。该理论模型可不依赖于材料的本构模型，能为杯形件拉深制耳的研究提供参考。

关键词: 制耳, 理论模型, 各向异性, 拉深试验, 2219-O铝合金

Abstract: Due to the in-plane anisotropy of the material, wavy earing defects occur during cup drawing. In order to accurately predict earing, in view of the limitations of the existing theoretical model only considering uniaxial compression deformation, on the basis of considering the biaxial stress state of the micro-body and the influence of radial non-uniform deformation, a new theoretical model for quantitative prediction of earing characteristics (including earing number, position and cup wall height) of cup-shaped parts is proposed. The accuracy of the theoretical model is verified by finite element analysis and experiments of deep drawing cup-shaped parts of 2219-O aluminum alloy sheet. The results show that the number of earings is the same as the maximum value of the in-plane anisotropic coefficients, the cup height increases monotonically with the anisotropic coefficient r_θ+90, the maximum and minimum positions of the cup height correspond to the maximum and minimum positions of r_θ+90. The maximum position of r_θ+90 corresponds to the earing peak, the minimum position corresponds to the earing trough. Comparing the earing characteristics under different initial blank diameters, the theoretically predicted earing number is exactly the same as the experiments, the position of the wave trough is exactly the same, and the position of the earing peak has a slight error, and the maximum error does not exceed 4°. The prediction accuracy of cup height and earing height is significantly better than that of the existing theoretical model, and the prediction accuracy has better consistency for initial blank with different diameters. The theoretical model does not depend on the constitutive model of the material, and can provide a reference for the study of cup earing.

Key words: ear, theoretical model, anisotropy, deep drawing experiment, 2219-O aluminum alloy

中图分类号:

TG386

林艳丽, 王家明, 刘军鹏, 苏一博, 王硕, 何祝斌. 金属薄板杯形件拉深制耳定量预测理论模型[J]. 机械工程学报, 2025, 61(4): 96-106.

LIN Yanli, WANG Jiaming, LIU Junpeng, SU Yibo, WANG Shuo, HE Zhubin. Theoretical Model for Quantitative Prediction of Earing Profile in Deep Drawing of Sheet Metal Cup-shaped Parts[J]. Journal of Mechanical Engineering, 2025, 61(4): 96-106.

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