CN111323319A - Method for evaluating high-speed impact hydraulic forming performance of metal plate - Google Patents
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/32—Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces
- G01N3/34—Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces generated by mechanical means, e.g. hammer blows
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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
- B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
- B21D26/02—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces by applying fluid pressure
- B21D26/021—Deforming sheet bodies
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- G01N2203/0032—Generation of the force using mechanical means
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- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
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- G01N2203/0067—Fracture or rupture
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Abstract
The invention discloses a method for evaluating high-speed impact hydraulic forming performance of a metal plate, and belongs to the field of evaluation of room-temperature forming capability of plate parts. The evaluation method is based on a high-energy-rate impact hydroforming process, and determines the unit area impact energy required by parts of various specifications under the conditions of incomplete deformation, complete deformation and cracking by performing impact hydroforming on a series of circular plate parts with different deformation ratios, so that the deformation energy and the state of the plate under different deformation ratios can be determined quickly. The method can determine the difference of the forming capacity of different materials at a high strain rate, and the change condition of the forming capacity of a certain material at the high strain rate is determined, and meanwhile, the method can quantitatively determine an impact hydroforming process window for the certain determined material.
Description
Technical Field
The invention relates to the technical field of plate high-speed forming capability evaluation, in particular to a method for evaluating high-speed impact hydraulic forming performance of a metal plate.
Background
Aiming at the problem of low room temperature forming capability of metals such as aluminum, magnesium and the like, the solution scheme mainly has two approaches: on one hand, warm forming is adopted, so that the intrinsic forming capability of the material is improved; on the other hand, by using high-speed forming means such as explosion forming, electromagnetic forming, laser shock forming, etc., the room-temperature forming ability of the hardly deformable material can be improved. The forming method of the invention relies on impact hydraulic forming, the technological principle is that liquid is hit by an impact body running at high speed, the liquid acts on a blank contacted with the liquid in the form of impact wave after obtaining impact energy, so that the material is subjected to plastic deformation to obtain a part with a specified shape and a specified structural size.
However, a method for evaluating the forming capability of a sheet material based on a high-speed forming mode is not established, and the method still depends on a traditional sheet material quasi-static forming limit curve or forming limit diagram, and judges the forming capability of the material under the premise of different strain paths by analyzing the relative relationship between primary strain and secondary strain, although the forming limit of the material under each strain path can be quantitatively given, the forming capability of the material under the deformation process condition of high-speed deformation of a flexible medium cannot be well represented. In addition, high-speed forming modes such as impact hydroforming, electro-hydraulic forming and the like have the function of liquid media, the problem of leakage of a dog-bone-shaped sample must be solved in the process of carrying out traditional forming limit evaluation, and the existing method adopts a substrate to prevent leakage, but the friction and stress strain state of the tested sample can be changed, so that the evaluation result of the forming performance is greatly influenced.
In addition, the stress state of the traditional forming limit evaluating method is greatly different from the technological processes such as impact hydraulic pressure and the like, in the traditional forming limit evaluating method, a sample is in a bulging state and does not have radial feeding and supplementing materials, in the actual forming process, deformation of a plurality of plates is in a drawing-bulging composite state or a simple drawing state, and the forming performance of the materials under the actual working condition needs to be represented.
In addition, the traditional method for obtaining the forming limit of the material by drawing with a rigid punch only can reflect the limit forming capability of the material under the quasi-static condition and is not equal to the forming capability of the material under the high strain rate. Therefore, it is necessary to develop and establish an evaluation method and standard for the forming capability of the material aiming at the processes of electro-hydraulic forming, laser shock forming, shock hydraulic forming and the like.
Disclosure of Invention
The invention aims to provide a method for evaluating the high-speed impact hydroforming performance of a metal plate, which is a determination method for evaluating the drawing-bulging composite deformability of a sheet material under high-strain-rate deformation modes such as impact hydroforming and the like. The tensile forming capability of a certain material under the flexible impact load is determined by the simplest sample structure and size and the fewest experimental times, and a quantitative test and characterization method and theoretical guidance are provided for the formulation of the forming process.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a method for evaluating the high-speed impact hydroforming performance of a metal plate comprises the following steps:
(1) determining the deformation ratio and the initial blank diameter of an experimental sample according to the cavity diameter of the concave die of the hydraulic deformation die, and generally setting the number of groups of the samples to be 7-11 groups according to different initial blank diameters (namely different deformation ratios); according to the different impact energies required under different deformation states with the same initial blank diameter (namely the same deformation ratio), the number of each group of samples is usually set to be 6-15;
(2) performing an impact hydroforming experiment on a certain diameter sample, firstly controlling the impact energy of a unit area at a small value to enable the sample to reach an incomplete deformation state, recording the impact velocity value and calculating the impact energy of the unit area under the state, repeating the experiment for 3 times according to the energy, stopping the experiment and recording data if the experimental data of 3 times are consistent, taking the average value of the 3 experiments as the result of the impact energy of the unit area, continuing the experiment if the experimental results of 3 times are scattered, stopping the experiment and recording the data until the relative error of the experimental results of three times is less than 10%, and selecting the required data according to the principle;
(3) continuing to increase the initial unit area impact energy until complete deformation is realized, recording an impact velocity value, calculating the unit area impact energy in the state, and performing repeated experiments and selection of experimental data according to the principle of repeated experiments and data selection in the step (2);
(4) sequentially carrying out impact hydroforming experiments of other deformation ratio samples according to the data recording and selecting principles of the experiment steps in the step (2) and the step (3), and recording related experiment data;
(5) continuing to perform forming experiments of other deformation ratio samples according to the steps (1) to (4), finding out a group of the samples with cracking defects for the first time, continuing to perform forming experiments 2-3 groups of the samples with larger deformation ratio, selecting the group before cracking, continuing to increase unit area impact energy, enabling the samples to crack at the bottom arc after complete deformation, and performing repeated experiments and selection of experimental data according to the principle of repeated experiments and data selection in the step (2);
(6) selecting experimental data of each group before the sample cracks to perform fitting, and obtaining a complete deformation boundary curve of the material impact hydraulic pressure, so as to distinguish incomplete deformation and complete deformation areas of the sample;
(7) selecting experimental data of each group after the sample begins to crack, and fitting to obtain a boundary curve of the material impact hydraulic deformation cracking, so as to distinguish incomplete deformation and cracking areas of the sample;
(8) properly extending the deformation boundary curve obtained in the step (6) to enable the deformation boundary curve to be intersected with the cracking boundary curve obtained in the step (7), wherein the deformation ratio value corresponding to the intersection point is defined as the limit deformation ratio of the material under the impact hydroforming process;
the invention has the advantages that:
(1) the method can determine the difference of the forming capacities of different materials at high strain rates, and determine the high strain rate forming limit of the different materials, and secondly, the method can determine the strain rate threshold range of the improvement of the forming capacity of the materials, can quantitatively determine an impact hydroforming process window for a certain determined material, establishes the corresponding relation between the deformation ratio of the determined material and the impact energy in unit area, provides exact guidance for the determination of the material and the formation of a sample with the deformation ratio, effectively controls the sample to realize two different states of incomplete deformation and complete deformation, and effectively avoids the defect of cracking;
(2) the structure and the size of a sample related to the material forming performance evaluation method are simple, the basic structure of the sample is circular, the processing and the preparation are convenient, the diameters of different initial blanks are determined according to the diameter of a female die of a test die, and the change of any numerical value of the deformation ratio is realized in the simplest mode;
(3) the ultimate deformation ratio of the material under the impact load can be conveniently and quickly obtained by fitting the deformation curve and the cracking curve, a powerful quantitative theoretical basis is provided for determining the deformation process, the forming is carried out below the ultimate deformation ratio, the complete deformation can be realized, the safety domain is wide, the forming is carried out above the ultimate deformation ratio, the complete deformation cannot be realized, the deformation can be carried out only below the ultimate energy, the size of the forming energy needs to be strictly controlled, the cracking defect is prevented, and meanwhile, on the premise of realizing the specific deformation requirement, the waste of the impact energy can be effectively reduced, the energy is saved, and the emission is reduced;
(4) in the test process of the evaluation method, the same blank holder force value is kept, the effective feeding and material supplementing of a sample are ensured, the self-adaptive effect of liquid as a flexible medium is truly embodied, the defect of underestimation of forming capability caused by different stress states of a plate due to rigid contact of a traditional punch is prevented, and the forming capability of the material in a drawing-bulging composite forming state can be effectively reflected;
(5) the impact hydroforming equipment supported by the invention has large capacity, and the covered strain rate range is wider and can reach 102～105And/s, the deformation performance of various common material plates with the thickness of 0.2-4 mm can be quickly evaluated, the evaluation experiment of the forming performance of samples with different thicknesses can be realized by adjusting the thickness of the cushion plate, and the method is convenient and quick.
(7) The evaluation method is based on a high-energy-rate impact hydroforming process, and determines the unit area impact energy required by parts of various specifications under the conditions of incomplete deformation, complete deformation and cracking by performing impact hydroforming on a series of circular plate parts with different deformation ratios, so that the deformation energy and the state of the plate under different deformation ratios can be determined quickly. The method can determine the difference of the forming capacity of different materials at a high strain rate, and the change condition of the forming capacity of a certain material at the high strain rate is determined, and meanwhile, the method can quantitatively determine an impact hydroforming process window for the certain determined material.
(8) The forming capability evaluating method provided by the invention has the advantages of less test times, capability of quickly determining the size of the limit deformation ratio of the plate, simple part structure and size, simple experimental operation and easy realization, and provides quantitative theoretical guidance for the development of the part deep drawing forming process by adopting the method. The method for evaluating the forming capability of the plate at the high strain rate can also be applied to high-speed forming processes such as electro-hydraulic forming, laser shock peening forming and the like.
Drawings
Fig. 1 is a diagram of initial sample structure and dimensions.
FIG. 2 is a schematic diagram showing the evaluation test principle and the definition of the deformation ratio.
Fig. 3 shows the data points required for the deformation curve determination.
Fig. 4 is a determination of a full deformation curve.
FIG. 5 is a data point required for crack curve determination.
Fig. 6 is a determination of the maximum of the cracking curve.
FIG. 7 is a determination of a cracking curve.
Fig. 8 is a determination of the limit deformation ratio.
Detailed Description
For a further understanding of the present invention, the following description is given in conjunction with the examples which are set forth to illustrate, but are not to be construed to limit the present invention, features and advantages.
Example 1:
the initial sample structure and dimensions of this example are shown in fig. 1, and the evaluation process of the high-speed impact hydroforming capability of the plate is as follows:
(1) determining the deformation ratio of an experimental sample and the diameter of an initial blank (figure 2) according to the diameter of a cavity of a hydraulic deformation die, ensuring that the deformation ratio of the experimental sample can cover the limit deformation ratio of a material (the limit deformation ratio refers to the deformation ratio of the sample when the sample cracks), setting the number of groups of samples to be 7, setting the number of samples in each group to be 12, in the embodiment, the diameter of a deformation female die is set to be 40mm, the material is a certain two-series aluminum alloy 1.2mm thick plate, the limit deformation ratio obtained by drawing the quasi-static rigid punch of the material is about 1.89, and the deformation ratio of each group of samples is set to be 1.42, 1.51, 1.6, 1.77, 1.95, 2.13 and 2.31 according to the selected 7 groups of experimental samples, and the corresponding diameters of the initial blank are respectively 56.8mm, 60.4mm, 64mm, 70.8mm, 78mm, 85.2mm and 92.4;
(2) taking a sample (with an initial diameter of 56.8mm) with a minimum deformation ratio of 1.42 as an example, performing an impact hydraulic experiment, firstly enabling the sample to reach an incomplete deformation state, recording an impact velocity value, calculating unit area impact energy under the state, repeating the experiment for 3 times according to the energy, stopping the experiment and recording data if the data of the experiment of 3 times are consistent, and taking the average value (61.6 kJ/m) of the experiments of 3 times2) As a result of the impact energy per unit area;
(3) and continuously increasing the initial unit area impact energy until complete deformation is realized, recording the impact velocity value, calculating the unit area impact energy in the state, repeating the experiment for 3 times according to the impact velocity, and taking the average value as the unit area impact energy value which is 129.4kJ/m2；
(4) According to the data recording and selecting principle of the experiment step (2), the impact hydraulic deformation experiments of other groups of samples are sequentially carried out, the related experiment data are recorded, the number of the groups for carrying out the experiments is 7, and the obtained maximum unit area impact energy in the incomplete deformation state is 129.2kJ/m2、225.4kJ/m2、485.1kJ/m2、1212.6kJ/m2、1097.2kJ/m2、755.9kJ/m2；；
(5) Performing deformation experiments on samples with different deformation ratios according to the steps, finding out the group of the samples with the first cracking defect, namely the 6 th group of samples begin to crack, selecting the group before cracking (namely the 5 th group of samples), increasing the impact energy per unit area, enabling the bottom arc of the samples to crack after complete deformation, and continuously performing three times of impact experiments, wherein the numerical difference of the impact energy per unit area is small, and the minimum impact energy per unit area during cracking is 2378.4kJ/m2Recording the data; (see fig. 3-5).
(6) The experimental data of each group before the sample cracks are selected for fitting (generally, a nonlinear change relation is satisfied), the embodiment adopts polynomial fitting, and the fitting adopts a formula form as follows:
y＝A+B*x+C*x2+D*x3
the curve expression obtained after fitting is:
E＝-33007.7+63475.6x-41039.4x2+8982.6x3wherein x is a deformation ratio, the fitting coincidence degree reaches 0.98769, and an impact hydraulic complete deformation boundary curve of the material is obtained to distinguish incomplete deformation and complete deformation areas of the sample;
(7) the experimental data of each group after the sample is cracked are selected for fitting (generally, a nonlinear change relation is satisfied), the method for fitting is the asymptoic fitting method, and the formula for fitting is as follows:
y＝a+b*cxthe curve expression obtained after fitting is:
y＝695.1+1.05718×0.00105xwherein x is a deformation ratio, fitting the coincidence degree to 0.98964, and obtaining a fracture boundary curve of the material impacting hydraulic deformation to distinguish incomplete deformation and a fracture area of the sample (FIGS. 6-7);
(8) and (3) properly extending the deformation boundary curve obtained in the step (6) to enable the deformation boundary curve to intersect with the cracking boundary curve obtained in the step (7), wherein the deformation ratio value corresponding to the intersection point is defined as the limit deformation ratio of the material under the impact hydroforming process (figure 8), and the limit deformation ratio in the embodiment is 2.02.
Claims (9)
1. A method for evaluating the high-speed impact hydraulic forming performance of a metal plate is characterized by comprising the following steps: the method is used for evaluating the forming performance of the material in a high-speed impact hydraulic forming mode, and specifically comprises the following steps:
(1) determining the deformation ratio and the initial blank diameter of an experimental sample according to the cavity diameter of a concave die of a hydraulic deformation die, wherein the samples are arranged into 7-11 groups, each group of samples has different initial blank diameters, and the number of each group of samples is 6-15;
(2) in a certain deformation ratio range, along with the change of deformation energy, a sample has three different forming states of incomplete deformation (flange edge is not completely pulled into a female die), complete deformation (flange edge is completely pulled into the female die) and cracking, an impact hydroforming experiment is carried out on a certain diameter sample, firstly, the impact energy per unit area is controlled to be a small value A, so that the sample reaches the incomplete deformation state, the impact speed value is recorded, and the impact energy per unit area under the state is calculated;
(3) increasing the value of the impact energy per unit area to be B, continuing an impact hydroforming experiment on the sample until the sample is completely deformed, recording the impact velocity value and calculating the impact energy per unit area in the state;
(4) sequentially carrying out impact hydroforming experiments of other deformation ratio samples according to the processes of the steps (2) to (3), and recording related experimental data;
(5) continuing forming experiments of other groups of samples under different deformation ratios according to the steps (2) to (4), finding out a group of the samples with cracking defects for the first time, continuing forming experiments of the samples with larger deformation ratios for 2-3 groups, selecting the group before cracking, continuing increasing the unit area impact energy to enable the samples to crack at the bottom arc after complete deformation, and performing repeated experiments and selection of experimental data according to the step (2);
(6) selecting experimental data of each group before the sample cracks to carry out fitting (generally meeting a nonlinear change relation), and obtaining an impact hydraulic complete deformation boundary curve of the material to distinguish incomplete deformation and complete deformation areas of the sample;
(7) selecting experimental data of each group after the sample begins to crack to perform fitting (generally meeting the nonlinear change relation), and obtaining a boundary curve of the material for impacting hydraulic deformation and cracking so as to distinguish incomplete deformation and cracking areas of the sample;
(8) and (3) properly extending the deformation boundary curve obtained in the step (6) to enable the deformation boundary curve to intersect with the cracking boundary curve obtained in the step (7), wherein the deformation ratio value corresponding to the intersection point is defined as the limit deformation ratio of the material under the impact hydroforming process.
2. The method for evaluating the high-energy-rate impact hydroforming property of a metal plate according to claim 1, wherein: the deformation ratio is defined as the ratio of the diameter of the initial round plate blank to the inner diameter of the deformed cylindrical part, and the limit deformation ratio is the deformation ratio of the sample when the sample is cracked; the deformation ratio of the experimental sample is ensured to be selected to cover the limit deformation ratio of the material in the test process.
3. The method for evaluating the high-energy-rate impact hydroforming property of a metal plate according to claim 1, wherein: in the steps (2) - (3), the method for calculating the impact energy per unit area is to divide the impact energy by the effective contact action area between the liquid and the plate, repeat the experiment for 3 times according to the selected impact energy, stop the experiment and record data if the data of the experiment of 3 times are relatively consistent, take the average value of the experiment of 3 times as the result of the impact energy per unit area, continue the experiment if the results of the experiment of 3 times are relatively dispersed, stop the experiment and record data until the relative error of the results of the three experiments is less than 10%, and take the average value of the experiment as the result of the impact energy per unit area.
4. The method for evaluating the high-energy-rate impact hydroforming property of a metal sheet according to claim 1, wherein the method can evaluate the forming capability of the material in a large strain rate range, and the strain rate range can reach 102～105/s。
5. The method for evaluating the high-energy-rate impact hydroforming property of a metal plate according to claim 1, wherein the method can determine the difference of the forming ability of different materials at high strain rate to define the forming limit of the high strain rate of the different materials.
6. The method for evaluating the high-energy-rate impact hydroforming property of a metal plate according to claim 1, wherein the change of the forming ability of a certain material at a high strain rate can be determined, the strain rate threshold range of the improvement of the forming ability of the material can be determined, and the evaluation method can quantitatively determine the impact hydroforming process window for a certain determined material.
7. The method for evaluating the high-energy-rate impact hydroforming property of a metal sheet according to claim 1, wherein the high strain rate forming property determined by the evaluation method attempts to differentiate a two-dimensional space into three regions respectively representing an incomplete deformation region, a complete deformation region and a cracking region corresponding to three different forming states of the test specimen.
8. An evaluation method for high-energy-rate impact hydroforming property of metal sheets according to claim 1, characterized in that the evaluation method determines the magnitude of the ultimate deformation ratio through the intersection point of the deformation curve and the crack fitting curve, and the impact energy per unit area required for reaching the ultimate deformation ratio, so as to quantitatively determine the forming process and the limit of the material under study with higher accuracy.
9. The method of evaluating high energy rate impact hydroforming properties of sheet metal according to claim 1 wherein said method determines the impact energy per unit area for incomplete and complete deformation of a specimen at a deformation ratio less than a limiting deformation ratio and determines the impact energy per unit area for incomplete and complete deformation of a specimen at a deformation ratio greater than the limiting deformation ratio.
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Application publication date: 20200623 |