CN108637093B - Warm forming die for aluminum alloy hemispherical shell - Google Patents
Warm forming die for aluminum alloy hemispherical shell Download PDFInfo
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- CN108637093B CN108637093B CN201810403543.6A CN201810403543A CN108637093B CN 108637093 B CN108637093 B CN 108637093B CN 201810403543 A CN201810403543 A CN 201810403543A CN 108637093 B CN108637093 B CN 108637093B
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 43
- 238000003825 pressing Methods 0.000 abstract description 31
- 239000000463 material Substances 0.000 abstract description 5
- 229910052751 metal Inorganic materials 0.000 abstract description 5
- 239000002184 metal Substances 0.000 abstract description 5
- 238000009826 distribution Methods 0.000 abstract description 3
- 238000000034 method Methods 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 230000037303 wrinkles Effects 0.000 description 2
- 230000002411 adverse Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000001953 recrystallisation Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
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Abstract
本发明公开了一种铝合金半球形壳体温热成形模具，包括凸模、凹模以及能拆卸的固定在凹模上的压料板；所述凸模下部为内部具有空腔的半球体，半球体底部开设有圆形通孔；所述压料板上设置有通孔；所述凹模为带法兰的空心圆筒，凹模上端内缘设有圆角。本发明在凸模的半球体底部设计一个圆形通孔，一方面避免了凸模底部板坯与模具间的摩擦，减少凸模底部金属发生延伸变形的阻力，使底部材料更多地通过延伸变形补偿拉伸区域；另一方面，圆形通孔的设置也改变了拉伸加载位置，圆形通孔半径R1范围为R1＝k·R2，其中k为0.1～0.13，通过合理设计圆形通孔直径能够改变工件截面厚度分布，减小构件厚度减薄率，使其控制在10％以内。
The invention discloses a warm forming die for an aluminum alloy hemispherical shell, comprising a punch, a die and a detachable pressing plate fixed on the die; the lower part of the punch is a hemisphere with a cavity inside, The bottom of the hemisphere is provided with a circular through hole; the pressing plate is provided with a through hole; the concave die is a hollow cylinder with a flange, and the inner edge of the upper end of the concave die is provided with rounded corners. The present invention designs a circular through hole at the bottom of the hemisphere of the punch, which on the one hand avoids the friction between the slab at the bottom of the punch and the mould, reduces the resistance of the metal at the bottom of the punch to extend and deform, and allows the bottom material to pass more through the extension The deformation compensates the tensile area; on the other hand, the setting of the circular through hole also changes the tensile loading position. The radius R 1 of the circular through hole is in the range of R 1 =k·R 2 , where k is 0.1-0.13. Designing the diameter of the circular through hole can change the thickness distribution of the workpiece section and reduce the thickness thinning rate of the component, so that it can be controlled within 10%.
Description
技术领域technical field
本发明属于铝合金成形技术领域，具体是涉及到一种铝合金半球形壳体温热成形模具。The invention belongs to the technical field of aluminum alloy forming, and particularly relates to a warm forming die for an aluminum alloy hemispherical shell.
背景技术Background technique
航空航天以及民用贮箱罐体对气密性和减重的要求较高，常采用高强度铝合金，具有较高比强度和比刚度性能的铝合金罐体得到广泛应用。对于内径与壁厚比大于60的铝合金半球形贮箱底薄壁壳体构件成形，由于在加工余量与设备规格等方面的优点，现阶段国内仍主要沿用传统的瓜瓣拼焊成形技术。然而，由于铝合金焊接性能有限，且焊缝产生的内应力及性能弱化，因此会对构件的服役性能和加工精度产生不利影响。Aerospace and civil storage tanks have high requirements for air tightness and weight reduction, and high-strength aluminum alloys are often used. Aluminum alloy tanks with high specific strength and specific stiffness are widely used. For the forming of thin-walled aluminum alloy hemispherical tank bottom shell components with an inner diameter to wall thickness ratio greater than 60, due to the advantages of machining allowance and equipment specifications, the traditional tailor-welded forming technology is still mainly used in China at this stage. However, due to the limited welding performance of aluminum alloys and the weakening of the internal stress and performance of the weld, it will adversely affect the service performance and machining accuracy of the components.
而强度的提升往往降低了铝合金材料的室温塑性，成形范围有限，容易局部减薄过大，降低服役承载能力。此外，高强铝合金室温加工过程中产生较高的内应力以及微观缺陷还会导致薄壁壳体构件淬火时发生畸变，甚至开裂报废。However, the increase in strength often reduces the room temperature plasticity of the aluminum alloy material, and the forming range is limited, and it is easy to locally thin too much, reducing the service bearing capacity. In addition, the high internal stress and microscopic defects generated during the room temperature processing of high-strength aluminum alloys will also lead to distortion of thin-walled shell components during quenching, and even cracking and scrapping.
铝合金加热至一定温度后塑性和延伸率大幅提高，可有效提高板材的成形性并降低成形件残余应力，适用于性能和形状需求较高的高值小批量零件生产。成形过程中温度与成形速度的控制对于铝合金成形件的晶粒组态具有重要影响，如成形过程中的再结晶控制不足很容易造成铝合金成形件的疲劳、腐蚀等性能下降。而模具式的温热成形方法在温度和速度控制上具有结构上的优势，因此常用于成形精度和性能要求较高的构件成形制造中。After the aluminum alloy is heated to a certain temperature, the plasticity and elongation are greatly improved, which can effectively improve the formability of the sheet and reduce the residual stress of the formed parts. It is suitable for the production of high-value small-batch parts with high performance and shape requirements. The control of temperature and forming speed during the forming process has an important influence on the grain configuration of the aluminum alloy formed parts. For example, insufficient recrystallization control during the forming process can easily cause the fatigue and corrosion of the aluminum alloy formed parts to decline. The mold-type warm forming method has structural advantages in temperature and speed control, so it is often used in the forming and manufacturing of components with high forming accuracy and performance requirements.
但目前尚没有关于铝合金半球形壳体温热成形的模具的报道，因此急需弥补现有技术的空白，提供一种铝合金半球形壳体温热成形的模具。However, there is no report on a mold for warm forming of an aluminum alloy hemispherical shell at present, so it is urgent to make up for the blank of the prior art and provide a mold for warm forming of an aluminum alloy hemispherical shell.
发明内容SUMMARY OF THE INVENTION
本发明要解决的技术问题是弥补现有技术的空白，提供一种适用于铝合金半球形壳体温热成形的模具，该模具不仅结构简单、制作成本低，而且能够提高截面厚度分布均匀性，降低成形构件的减薄率。The technical problem to be solved by the present invention is to make up for the blank of the prior art, and to provide a mold suitable for the warm forming of aluminum alloy hemispherical shells. Reduce the thinning rate of formed components.
本发明的铝合金半球形壳体温热成形模具，包括凸模、凹模以及能拆卸的固定在凹模上的压料板；所述凸模下部为内部具有空腔的半球体，半球体底部开设有圆形通孔；所述压料板上设置有通孔；所述凹模为带法兰的空心圆筒，凹模上端内缘设有圆角。The aluminum alloy hemispherical shell warm forming mold of the present invention includes a punch, a concave die and a detachable pressing plate fixed on the concave die; the lower part of the punch is a hemisphere with a cavity inside, and the bottom of the hemisphere is A circular through hole is provided; the pressing plate is provided with a through hole; the concave die is a hollow cylinder with a flange, and the inner edge of the upper end of the concave die is provided with a rounded corner.
所述半球体的外半径为R2，所述圆形通孔的半径R1＝k·R2，其中k为0.1～0.13。The outer radius of the hemisphere is R 2 , and the radius of the circular through hole is R 1 =k·R 2 , where k is 0.1˜0.13.
所述凸模包括上模块和设置在上模块下部的下模块。The punch includes an upper module and a lower module arranged at the lower part of the upper module.
所述上模块包括外筒和固定在外筒底部的挡板，下模块包括内筒和固定在内筒上的位于挡板上部的挂环，还包括设置在内筒下方并与内筒固定连接的内部具有空腔的半球体，所述内筒的长度大于挡板的厚度，两者的高度差h为10～200mm。The upper module includes an outer cylinder and a baffle fixed at the bottom of the outer cylinder, the lower module includes an inner cylinder and a hanging ring located on the upper part of the baffle fixed on the inner cylinder, and also includes a lower part of the inner cylinder and fixedly connected to the inner cylinder. A hemisphere with a cavity inside, the length of the inner cylinder is greater than the thickness of the baffle, and the height difference h between the two is 10-200 mm.
优选的，所述具有空腔的半球体的壁厚t为50～300mm，优选为80～120mm。Preferably, the wall thickness t of the hemisphere with the cavity is 50-300 mm, preferably 80-120 mm.
本发明中模具半球体的外半径R2的适用范围为200～5000mm，因此圆形通孔的半径R1为20～650mm，优选为50～60mm。In the present invention, the applicable range of the outer radius R 2 of the mold hemisphere is 200-5000 mm, so the radius R 1 of the circular through hole is 20-650 mm, preferably 50-60 mm.
所述压料板的厚度为10～100mm，优选为15～30mm。The thickness of the pressing plate is 10-100 mm, preferably 15-30 mm.
所述凹模的壁厚为80～300mm，优选为100～150mm。The wall thickness of the die is 80-300 mm, preferably 100-150 mm.
所述圆角的半径R3为10～50mm，优选为15～25mm。The radius R 3 of the fillet is 10-50 mm, preferably 15-25 mm.
所述压料板和凹模上设置有固定孔，还包括插入到固定孔内的固定连接压料板和凹模的固定销孔。A fixing hole is arranged on the pressing plate and the female die, and also includes a fixing pin hole inserted into the fixing hole and fixedly connecting the pressing plate and the female die.
本发明的铝合金半球形壳体温热成形模具可安装于温热成形专用压力机上使用，也可安装于锻压机上并配备辅助加热保温筒使用。挡板和内筒结合的部分，称为定位凸台，成形前通过定位凸台与压料板中心的通孔配合定位，无需另外制作模架。The warm forming die for the aluminum alloy hemispherical shell of the present invention can be installed on a special press for warm forming, or can be installed on a forging press and equipped with an auxiliary heating and heat preservation cylinder. The part where the baffle plate and the inner cylinder are combined is called the positioning boss. Before forming, the positioning boss is matched with the through hole in the center of the pressing plate for positioning, and there is no need to make another mold base.
本发明的有益效果：Beneficial effects of the present invention:
(1)本发明在凸模的半球体底部设计一个圆形通孔，一方面避免了凸模底部板坯与模具间的摩擦，减少了凸模底部金属发生延伸变形的阻力，使底部材料更多地通过延伸变形补偿拉伸区域；另一方面，圆形通孔的设置也改变了拉伸加载位置，通过合理设计圆形通孔的直径能够改变工件截面厚度分布，减小构件厚度减薄率，使其控制在10％以内。(1) The present invention designs a circular through hole at the bottom of the hemisphere of the punch, which avoids the friction between the punch bottom slab and the die on the one hand, reduces the resistance to the extension and deformation of the punch bottom metal, and makes the bottom material more durable. The stretching area is often compensated by extension and deformation; on the other hand, the setting of the circular through hole also changes the tensile loading position. By rationally designing the diameter of the circular through hole, the thickness distribution of the workpiece cross-section can be changed, reducing the thickness and thinning of the component. rate, so that it is controlled within 10%.
(2)本发明中凹模内壁不与板坯接触且内缘半径尺寸合理设计，控制板料的流动，也能够起到控制法兰起皱和截面厚度减薄的效果。(2) In the present invention, the inner wall of the concave die is not in contact with the slab, and the radius of the inner edge is reasonably designed to control the flow of the sheet material, and can also control the wrinkling of the flange and the reduction of the thickness of the section.
(3)本发明中凹模的空心圆筒结构能够在板料成形过程中起到保温作用，有利于板料成形温度稳定。(3) The hollow cylindrical structure of the die in the present invention can play a role of heat preservation during the sheet metal forming process, which is beneficial to the stability of the sheet metal forming temperature.
(4)本发明中凸模上模块与下模块可以采用整体形式，也可以采用组合形式，组合形式的下模块可以设计为一系列不同型面的结构，从而可以根据成形件灵活更换，可以降低模具生产成本，提高生产效率。(4) In the present invention, the upper module and the lower module of the punch can be in an integral form or in a combined form, and the lower module in the combined form can be designed as a series of structures with different profiles, so that it can be flexibly replaced according to the formed parts, which can reduce the Mold production cost, improve production efficiency.
(5)本发明所述减薄率的测算方法，沿半球形壳体径向剖开，在剖面上间隔1cm分散取点测量截面厚度，减薄率＝(板坯厚度－成形件最小厚度)/板坯厚度×100％。(5) The method for calculating the thinning rate according to the present invention is to cut the hemispherical shell radially, and measure the thickness of the section at a distance of 1 cm on the section. Thinning rate = (the thickness of the slab - the minimum thickness of the formed part) / Slab thickness × 100%.
附图说明Description of drawings
图1为本发明的铝合金半球形壳体温热成形模具的主视结构示意图。FIG. 1 is a schematic front view of the structure of the warm forming die for the aluminum alloy hemispherical shell of the present invention.
图2为本发明的凸模的结构示意图。FIG. 2 is a schematic structural diagram of the punch of the present invention.
在图中，1-凸模，2-压料板，21-通孔，3-凹模，4-上模块，41-外筒，42-挡板，5-下模块，51-内筒，52-挂环，53-半球体，531-圆形通孔，6-固定销孔，7-固定孔。In the figure, 1-punch, 2-press plate, 21-through hole, 3-female die, 4-upper module, 41-outer cylinder, 42-baffle plate, 5-lower module, 51-inner cylinder, 52-hanging ring, 53-hemisphere, 531-round through hole, 6-fixing pin hole, 7-fixing hole.
具体实施方式Detailed ways
以下结合附图和实施例对本发明做进一步说明。The present invention will be further described below with reference to the accompanying drawings and embodiments.
如图1、图2所示，成形目标为半径200～5000mm的铝合金半球形壳体。模具由凸模、压料板、凹模组成。凸模采用上模块和下模块构成的整体形式或组合形式，下模块的半球体的球面外径R2为200～5000mm，取值与成形目标一致，半球体的球面壁厚t为50～300mm，下模块的半球体底部中心设有半径R1为20～650mm的圆形通孔，且R1＝k·R2，其中k为与材料相关的系数，k＝0.1～0.13。定位凸台高度h为10～200mm，压料板为厚度为10～100mm的空心板，凹模为壁厚为80～300mm的带法兰空心圆筒形结构，凹模上端内缘设有半径R3＝10～50mm的圆角，凹模上端外缘附近及压料板对应位置设有相同直径10～50mm的固定销孔和固定孔。As shown in Figure 1 and Figure 2, the forming target is an aluminum alloy hemispherical shell with a radius of 200 to 5000 mm. The mold consists of a punch, a pressing plate, and a concave die. The punch adopts an integral form or a combined form composed of an upper module and a lower module. The spherical outer diameter R2 of the hemisphere of the lower module is 200-5000mm , the value is consistent with the forming target, and the spherical wall thickness t of the hemisphere is 50-300mm , the bottom center of the hemisphere of the lower module is provided with a circular through hole with a radius R 1 of 20-650 mm, and R 1 =k·R 2 , where k is a material-related coefficient, k=0.1-0.13. The height h of the positioning boss is 10-200mm, the pressing plate is a hollow plate with a thickness of 10-100mm, the die is a hollow cylindrical structure with a flange with a wall thickness of 80-300mm, and the inner edge of the upper end of the die is provided with a radius R 3 = 10-50mm rounded corners, fixing pin holes and fixing holes with the same diameter of 10-50mm are arranged near the outer edge of the upper end of the die and the corresponding position of the pressing plate.
实施例1Example 1
采用图1、图2所示的铝合金半球形壳体温热成形模具，成形目标为直径800mm的铝合金半球形壳体，板坯采用12mm厚2195-O铝合金板。模具由凸模、压料板、凹模组成，凸模采用上模块和下模块构成的整体形式，下模块中的半球体底部中心设有半径R1为52mm(k＝0.13)的圆形通孔，下模块的半球体的球面外半径R2为400mm，半球体的球面壁厚t为80mm，定位凸台高度h为30mm。压料板是厚度为15mm的空心圆板，凹模为壁厚为100mm的带法兰空心圆筒形结构，凹模上端的内缘圆角半径R3为20mm，凹模上端外缘附近及压料板对应位置设有直径为10mm的固定销孔和固定孔。The aluminum alloy hemispherical shell shown in Fig. 1 and Fig. 2 is used for warm forming mold, the forming target is an aluminum alloy hemispherical shell with a diameter of 800mm, and the slab is made of a 12mm thick 2195-O aluminum alloy plate. The mold consists of a punch, a pressing plate, and a concave die. The punch adopts an integral form composed of an upper module and a lower module. The center of the bottom of the hemisphere in the lower module is provided with a circular hole with a radius R 1 of 52mm (k=0.13). The outer radius R2 of the hemisphere of the lower module is 400mm, the spherical wall thickness t of the hemisphere is 80mm, and the height h of the positioning boss is 30mm. The pressing plate is a hollow circular plate with a thickness of 15mm. The concave die is a hollow cylindrical structure with a flange with a wall thickness of 100mm. The inner edge fillet radius R3 of the upper end of the die is 20mm. There are fixed pin holes and fixed holes with a diameter of 10mm at the corresponding position of the pressing plate.
成形前，先将板坯放在凹模上方，再将压料板放在板坯上方，并采用定位件穿过固定销孔和固定孔以实现压料板和板坯的固定，最后通过定位凸台与压料板中心的通孔配合定位，之后保持凸模下压速度为0.2mm/s、成形温度为420℃的条件进行成形。最终得到的成形构件最大减薄率为4.8％，法兰区无起皱。Before forming, first place the blank above the die, then place the blank holder above the blank, and use the positioning piece to pass through the fixing pin holes and fixing holes to achieve the fixing of the blank holder and the blank, and finally pass the positioning piece. The boss is positioned with the through hole in the center of the blanking plate, and then the pressing speed of the punch is 0.2mm/s and the forming temperature is 420°C for forming. The maximum thinning rate of the final formed component is 4.8%, and there is no wrinkle in the flange area.
实施例2Example 2
采用图1、图2所示的铝合金半球形壳体温热成形模具，成形目标为直径1200mm的铝合金半球形壳体，板坯采用8mm厚2050-O铝合金板。模具由凸模、压料板、凹模组成，凸模采用上模块和下模块的组合形式，下模块中的半球体底部中心设有半径R1为60mm(k＝0.1)的圆形通孔，下模块的半球体的球面外半径R2为600mm，半球体的球面壁厚t为120mm，定位凸台高度h为40mm。压料板是厚度为25mm的空心圆板，凹模为壁厚为150mm的带法兰空心圆筒形结构，凹模上端的内缘圆角半径R3为25mm，凹模上端外缘附近及压料板对应位置设有直径为15mm的固定销孔和固定孔。The aluminum alloy hemispherical shell as shown in Fig. 1 and Fig. 2 is used for warm forming mold, the forming target is an aluminum alloy hemispherical shell with a diameter of 1200mm, and the slab is made of 8mm thick 2050-O aluminum alloy plate. The mold consists of a punch, a pressing plate, and a concave die. The punch adopts a combination of an upper module and a lower module. The center of the bottom of the hemisphere in the lower module is provided with a circular through hole with a radius R 1 of 60mm (k=0.1). , the spherical outer radius R 2 of the hemisphere of the lower module is 600mm, the spherical wall thickness t of the hemisphere is 120mm, and the height h of the positioning boss is 40mm. The pressing plate is a hollow circular plate with a thickness of 25mm, the concave die is a hollow cylindrical structure with a flange with a wall thickness of 150mm, and the inner edge fillet radius R3 of the upper end of the concave die is 25mm. There are fixed pin holes and fixed holes with a diameter of 15mm at the corresponding position of the pressing plate.
成形前，先将板坯放在凹模上方，再将压料板放在板坯上方，并采用定位件穿过固定销孔和固定孔以实现压料板和板坯的固定，最后通过定位凸台与压料板中心的通孔配合定位，之后保持凸模下压速度为0.3mm/s、成形温度为400℃的条件进行成形。最终得到的成形构件最大减薄率为6.3％，法兰区无起皱。Before forming, first place the blank above the die, then place the blank holder above the blank, and use the positioning piece to pass through the fixing pin hole and fixing hole to achieve the fixing of the blank holder and the blank, and finally pass the positioning piece. The boss is positioned with the through hole in the center of the blanking plate, and then the pressing speed of the punch is 0.3mm/s and the forming temperature is 400°C for forming. The maximum thinning rate of the final formed component is 6.3%, and there is no wrinkle in the flange area.
对比例1Comparative Example 1
采用图1、图2所示的铝合金半球形壳体温热成形模具，成形目标为直径800mm的铝合金半球形壳体，板坯采用12mm厚2195-O铝合金板。模具由凸模、压料板、凹模组成，凸模采用上模块和下模块构成的整体形式，下模块中的半球体底部中心无圆形通孔，下模块的半球体的球面外半径R2为400mm，半球体的球面壁厚t为80mm，定位凸台高度h为30mm。压料板是厚度为15mm的空心圆板，凹模为壁厚为100mm的带法兰空心圆筒形结构，凹模上端的内缘圆角半径R3为20mm，凹模上端外缘附近及压料板对应位置设有直径为10mm的固定销孔和固定孔。The aluminum alloy hemispherical shell shown in Fig. 1 and Fig. 2 is used for warm forming mold, the forming target is an aluminum alloy hemispherical shell with a diameter of 800mm, and the slab is made of a 12mm thick 2195-O aluminum alloy plate. The mold consists of a punch, a pressing plate, and a concave die. The punch adopts an integral form composed of an upper module and a lower module. There is no circular through hole in the center of the bottom of the hemisphere in the lower module, and the spherical outer radius of the hemisphere of the lower module is R. 2 is 400mm, the spherical wall thickness t of the hemisphere is 80mm, and the height h of the positioning boss is 30mm. The pressing plate is a hollow circular plate with a thickness of 15mm. The concave die is a hollow cylindrical structure with a flange with a wall thickness of 100mm. The inner edge fillet radius R3 of the upper end of the die is 20mm. There are fixed pin holes and fixed holes with a diameter of 10mm at the corresponding position of the pressing plate.
成形前，先将板坯放在凹模上方，再将压料板放在板坯上方，并采用定位件穿过固定销孔和固定孔以实现压料板和板坯的固定，最后通过定位凸台与压料板中心的通孔配合定位，之后保持凸模下压速度为0.2mm/s、成形温度为420℃的条件进行成形。最终得到的成形构件最大减薄率为17％。Before forming, first place the blank above the die, then place the blank holder above the blank, and use the positioning piece to pass through the fixing pin hole and fixing hole to achieve the fixing of the blank holder and the blank, and finally pass the positioning piece. The boss is positioned with the through hole in the center of the blanking plate, and then the pressing speed of the punch is 0.2mm/s and the forming temperature is 420°C for forming. The maximum thinning rate of the final formed member is 17%.
对比例2Comparative Example 2
采用图1、图2所示的铝合金半球形壳体温热成形模具，成形目标为直径800mm的铝合金半球形壳体，板坯采用12mm厚2195-O铝合金板。模具由凸模、压料板、凹模组成，凸模采用上模块和下模块构成的整体形式，下模块中的半球体底部中心设有半径R1为30mm的圆形通孔，下模块的半球体的球面外半径R2为400mm，半球体的球面壁厚t为80mm，定位凸台高度h为30mm。压料板是厚度为15mm的空心圆板，凹模为壁厚为100mm的带法兰空心圆筒形结构，凹模上端的内缘圆角半径R3为20mm，凹模上端外缘附近及压料板对应位置设有直径为10mm的固定销孔和固定孔。The aluminum alloy hemispherical shell shown in Fig. 1 and Fig. 2 is used for warm forming mold, the forming target is an aluminum alloy hemispherical shell with a diameter of 800mm, and the slab is made of a 12mm thick 2195-O aluminum alloy plate. The mold consists of a punch, a pressing plate, and a concave die. The punch adopts an integral form composed of an upper module and a lower module. The center of the bottom of the hemisphere in the lower module is provided with a circular through hole with a radius of R 1 of 30mm. The spherical outer radius R2 of the hemisphere is 400mm, the spherical wall thickness t of the hemisphere is 80mm, and the height h of the positioning boss is 30mm. The pressing plate is a hollow circular plate with a thickness of 15mm. The concave die is a hollow cylindrical structure with a flange with a wall thickness of 100mm. The inner edge fillet radius R3 of the upper end of the die is 20mm. There are fixed pin holes and fixed holes with a diameter of 10mm at the corresponding position of the pressing plate.
成形前，先将板坯放在凹模上方，再将压料板放在板坯上方，并采用定位件穿过固定销孔和固定孔以实现压料板和板坯的固定，最后通过定位凸台与压料板中心的通孔配合定位，之后保持凸模下压速度为0.2mm/s、成形温度为420℃的条件进行成形。最终得到的成形构件最大减薄率为11％。Before forming, first place the blank above the die, then place the blank holder above the blank, and use the positioning piece to pass through the fixing pin holes and fixing holes to achieve the fixing of the blank holder and the blank, and finally pass the positioning piece. The boss is positioned with the through hole in the center of the blanking plate, and then the pressing speed of the punch is 0.2mm/s and the forming temperature is 420°C for forming. The maximum thinning rate of the final formed member was 11%.
对比例3Comparative Example 3
采用图1、图2所示的铝合金半球形壳体温热成形模具，成形目标为直径800mm的铝合金半球形壳体，板坯采用12mm厚2195-O铝合金板。模具由凸模、压料板、凹模组成，凸模采用上模块和下模块构成的整体形式，下模块中的半球体底部中心设有半径R1为60mm的圆形通孔，下模块的半球体的球面外半径R2为400mm，半球体的球面壁厚t为80mm，定位凸台高度h为30mm。压料板是厚度为15mm的空心圆板，凹模为壁厚为100mm的带法兰空心圆筒形结构，凹模上端的内缘圆角半径R3为20mm，凹模上端外缘附近及压料板对应位置设有直径为10mm的固定销孔和固定孔。The aluminum alloy hemispherical shell shown in Fig. 1 and Fig. 2 is used for warm forming mold, the forming target is an aluminum alloy hemispherical shell with a diameter of 800mm, and the slab is made of a 12mm thick 2195-O aluminum alloy plate. The mold consists of a punch, a pressing plate, and a concave die. The punch adopts an integral form composed of an upper module and a lower module. The center of the bottom of the hemisphere in the lower module is provided with a circular through hole with a radius R 1 of 60mm. The spherical outer radius R2 of the hemisphere is 400mm, the spherical wall thickness t of the hemisphere is 80mm, and the height h of the positioning boss is 30mm. The pressing plate is a hollow circular plate with a thickness of 15mm. The concave die is a hollow cylindrical structure with a flange with a wall thickness of 100mm. The inner edge fillet radius R3 of the upper end of the die is 20mm. There are fixed pin holes and fixed holes with a diameter of 10mm at the corresponding position of the pressing plate.
成形前，先将板坯放在凹模上方，再将压料板放在板坯上方，并采用定位件穿过固定销孔和固定孔以实现压料板和板坯的固定，最后通过定位凸台与压料板中心的通孔配合定位，之后保持凸模下压速度为0.2mm/s、成形温度为420℃的条件进行成形。最终得到的成形构件最大减薄率为10.3％。Before forming, first place the blank above the die, then place the blank holder above the blank, and use the positioning piece to pass through the fixing pin hole and fixing hole to achieve the fixing of the blank holder and the blank, and finally pass the positioning piece. The boss is positioned with the through hole in the center of the blanking plate, and then the pressing speed of the punch is 0.2mm/s and the forming temperature is 420°C for forming. The maximum thinning rate of the final formed member was 10.3%.
通过比较实施例1与对比例1可知，本发明在凸模下模块的半球体底部中心开设有圆形通孔，一方面避免了凸模底部板坯与模具间的摩擦，减少了凸模底部金属发生延伸变形的阻力，使底部材料更多地通过延伸变形补偿拉伸区域；另一方面，通过比较实施例1与对比例2～3可知，圆形通孔的设置也改变了拉伸加载位置，本发明的圆形通孔半径R1范围为R1＝k·R2，其中k为0.1～0.13，当模具的外半径R2固定时，圆形通孔半径R1范围固定，通过合理设计圆形通孔直径能够改变工件截面厚度分布，减小构件厚度减薄率(控制在10％以内)。By comparing Example 1 and Comparative Example 1, it can be seen that the present invention is provided with a circular through hole in the center of the hemispherical bottom of the lower module of the punch. The resistance of the metal to extend and deform makes the bottom material more compensate the tensile area through the extension and deformation; on the other hand, by comparing Example 1 and Comparative Examples 2 to 3, it can be seen that the setting of the circular through holes also changes the tensile loading position, the radius R 1 of the circular through hole in the present invention is in the range of R 1 =k·R 2 , where k is 0.1 to 0.13. When the outer radius R 2 of the mold is fixed, the radius R 1 of the circular through hole is fixed in the range. Reasonable design of the diameter of the circular through hole can change the thickness distribution of the workpiece section and reduce the thickness thinning rate of the component (controlled within 10%).
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