CN114770048A - One-time drawing thermal forming method for large-scale alloy aluminum plate - Google Patents
One-time drawing thermal forming method for large-scale alloy aluminum plate Download PDFInfo
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 29
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
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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
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
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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
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/20—Deep-drawing
- B21D22/208—Deep-drawing by heating the blank or deep-drawing associated with heat treatment
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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
- 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
- B21D37/18—Lubricating, e.g. lubricating tool and workpiece simultaneously
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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
- B21D53/00—Making other particular articles
- B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
Abstract
The invention discloses a one-time drawing thermal forming method of a large-sized alloy aluminum plate, which comprises the following steps: determining a plate and a forming die surface; inputting the data into CAE software, setting an amplification factor and simulating; manufacturing a drawing forming die according to a CAE simulation result; arranging a heating furnace and a punching machine tool, and assembling a drawing forming die on a thermal forming punching machine tool; determining the target temperature of the heating furnace, the shortest time for heating to the target temperature and the transfer time for transferring to a drawing forming die according to the plate; heating the plate according to the shortest time and the target temperature, and transferring the plate to a drawing forming die in the transfer time; stamping, pressure maintaining and laser cutting. The invention is suitable for processing large-scale, deep-drawn and complex-profile parts, has simple process, only needs one-time drawing thermal forming process, does not need to design a plurality of moulds, saves the stamping times, reduces the investment cost of equipment, fields and personnel, can be widely applied to the fields of automobile manufacturing, aviation, rail transit and the like, and has wide market prospect.
Description
Technical Field
The invention relates to an aluminothermic forming method, in particular to a one-time drawing and thermoforming method of a large-sized alloy aluminum plate.
Background
The existing aluminum plate forming process comprises an aluminum plate cold forming process and an aluminum plate hot forming process. The cold forming formability of the plate is poor, the maximum 20 percent of the thinning rate of the plate is the limit, and the product is cracked and other forming problems are generated beyond the range. In addition, the product design has a small R angle due to the process or modeling requirements of the product. These small R-angles, if formed by cold stamping aluminum, are often prone to cracking. For the situation, the modeling is changed, but once the modeling related to the appearance is changed, the selling point of the product can be lost, so that the competitiveness of a product manufacturer is lost; or the quality requirement is relaxed, so that the later quality control is difficult to control, and hidden troubles are buried for normal production; or a part is split into a plurality of parts, the process expenses of a die, stamping, welding and the like are correspondingly increased, and the vehicle manufacturing cost is increased.
In addition, the elastic modulus of the aluminum plate is one third of that of the steel plate, so that the cold forming rebound quantity of the aluminum is difficult to control. In the product processing, the shape is finished in the drawing process as much as possible, but the shape is also limited by the formability of the aluminum plate, and even if the quality of the product with rebound is improved to the required range, the cost in the process is quite high. According to the market quotation at present, the cold forming price of the aluminum plate of the same aluminum plate manufacturer is higher than that of the hot forming plate, and the price difference of the cold and hot aluminum plates is basically 1 ten thousand yuan/ton. Cold formed aluminum plates, unlike steel, have a limited shelf life, exemplified by 6000 series aluminum 6111T 4: the yield strength of the new material =130Mpa, yield strength after 6 months of storage =165Mpa, and if the storage time exceeds 6 months, the 6000 series aluminum material will be too hard to be formed. The procurement of raw materials of companies faces serious challenges, and the shortage of procurement amount faces the risk of supply interruption. Many raw materials are purchased for stock preparation, and once the time limit is exceeded, the raw materials cannot be used, so that batch scrapping is caused, and great economic loss is caused for companies.
The aluminothermic forming technology comprises a drawing mode and a hard forming mode with a pressure plate at the part of an upper die and a lower die, and the one-step drawing and thermoforming of the aluminum alloy is a drawing process in the aluminum alloy thermoforming mode. For parts processed by the aluminothermic forming technology, the elongation rate and the stretchability of materials are better, so that the aluminothermic forming technology is selected for large and deep parts. The parts manufactured by the aluminothermic forming technology have good shock absorption performance, can improve the safety during collision, and also have small density, small overall mass, reduced kinetic energy generated during collision and correspondingly reduced impact force. Therefore, the aluminum hot forming plate has wide application prospect, for example, the plate formed by the aluminum hot forming technology can be applied to the automobile industry under the trend of light weight development of automobiles. Besides, the method can be applied to the industries of aviation, rail transit and the like.
The part manufactured by the existing aluminothermic forming technology, wherein the part processed by the one-step drawing process, the development size of a plate material before forming is 1500mm long and 820mm wide, and the size of the formed part is 1100mm long, 710mm wide and 80mm deep. However, for some large-sized, deep-drawn and complex-profile parts such as automobile door inner panels, the parts cannot be formed by an aluminum alloy one-time drawing hot forming process, so that the existing aluminothermic forming technology cannot meet the processing of some parts with specific requirements.
The heat-treatable strengthened aluminum alloy and the non-heat-treatable strengthened aluminum alloy are selected mainly according to whether the plate materials have the heat-treatment strengthening effect, and in a phase diagram of the plate materials, a part of the plate materials are unidirectional solid solutions which do not generate structural change along with temperature change, and are called as non-heat-treatable strengthened aluminum alloys, such as 1, 3, 4 and 5 series aluminum alloys. Also, a part of the solid solution has a solubility varying with temperature, and can be heat-treated for strengthening, which is called heat-treatable strengthened aluminum alloy, such as aluminum alloys of 2, 6, and 7 series.
Disclosure of Invention
The invention aims to provide a one-time drawing thermal forming method for large-scale aluminum alloy plates, which solves the problems and is suitable for processing large-scale and deep-drawn parts.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows: a one-time drawing hot forming method of a large-scale alloy aluminum plate comprises the following steps;
(1) selecting a plate material according to the material of a finished product, designing a process supplement surface according to the profile of the finished product, and designing a forming die surface of a drawing forming die according to the profile of the finished product and the process supplement surface, wherein the plate material is a heat-treatable strengthened aluminum alloy, the thickness of the plate material is 1-5 mm, and the depth of the profile is less than or equal to 250 mm;
(2) inputting a plate and a forming die surface into CAE software, setting an amplification factor of 1.001-1.0019 in the CAE software, and carrying out CAE simulation according to a one-time drawing thermal forming process;
(3) adjusting the forming die surface, the amplification coefficient and CAE built-in parameters until the forming die surface capable of processing qualified finished products is obtained and used as an optimal die surface, determining the amplification coefficient corresponding to the optimal die surface, amplifying the optimal die surface according to the optimal die surface and the amplification coefficient corresponding to the optimal die surface, and manufacturing a drawing forming die according to the amplified optimal die surface;
(4) arranging a heating furnace and a punching machine according to the processing sequence, and assembling a drawing forming die on a thermal forming punching machine;
(5) the method comprises the steps of obtaining a curve of the formability of a plate in a heating furnace along with the change of temperature, determining the temperature when the plate reaches the optimal formability, determining a temperature range as a forming temperature window by taking the temperature as a center, presetting the transfer time of the plate transferred from the heating furnace to a drawing forming die to be 19-35s, determining the target temperature of the heating furnace according to the forming temperature window and the transfer time, wherein the target temperature can ensure that the plate is transferred from the heating furnace to the drawing forming die to just reach the forming temperature window, and obtaining the shortest time for the heating furnace to heat the plate to the target temperature;
(6) heating the plate according to the shortest time and the target temperature, and transferring the plate to a drawing forming die within the transfer time;
(7) setting the stamping speed of a stamping machine tool to be 400-450mm/s, and completing stamping;
(8) maintaining the pressure for 40-50 s at 800-820 ton to obtain a drawing process part;
(9) and (5) cutting off the process supplement surface by laser to obtain a finished product.
Preferably, the method comprises the following steps: in the step (1), the molding die surface comprises all the molded surface characteristics of the finished product and the molded surface characteristics corresponding to the flanging, the hole flanging and the positioning convex hull.
Preferably, the method comprises the following steps: in the step (3), the adjustment of the molding die surface specifically comprises the following steps: adjusting the shape of the process supplement surface, the size of the plate, the shape of the plate, the height of a draw bead, the position of the draw bead or the ejection height of a blank holder, wherein the CAE built-in parameters comprise: transfer time, press speed, or temperature of the draw forming die.
Preferably, the method comprises the following steps: and (4) coating a lubricant on a lubrication area of the drawing forming die, specifically, setting a thinning threshold, analyzing the qualified finished product in the step (3), and if the qualified finished product has thinning area and the thinning value is greater than or equal to the thinning threshold, determining the area as a thinning area, and determining the position, corresponding to the thinning area, on the drawing forming die as the lubrication area.
Preferably, the method comprises the following steps: and (5) measuring the temperature by adopting temperature sensors, uniformly selecting a plurality of point positions on the plate, arranging the temperature sensors, and judging that the whole plate reaches a temperature value when each temperature sensor reaches the temperature value. It should be noted that this step is only used in the early trial-manufacturing stage, and its main function is to verify the exact time for heating the sheet to the target temperature, i.e. the heating time of the sheet in the later production. And verifying whether the temperature uniformity of the plate meets the requirement in the heating time. During the mass production, point location equipment integrated in an automatic system is adopted to monitor the temperature of the plate materials in real time during the discharging, carrying and pressing.
Preferably, the method comprises the following steps: and a circulating cooling water channel is arranged on the drawing forming die, and a drawing process part is quenched by adopting the circulating cooling water channel during pressure maintaining.
Compared with the prior art, the invention has the advantages that:
(1) the novel method of the one-time drawing thermal forming process of the aluminum alloy is particularly suitable for processing large-scale, deep-drawing and parts with complex molded surfaces, the processing process is simple, taking an automobile door inner plate as an example, the working procedures in the prior art are mostly 4 sequences, and the working procedures are as follows: the invention relates to a method for manufacturing a drawing and trimming punching die, which comprises the steps of drawing, trimming and punching, flanging and reshaping, trimming and punching side punching, wherein the method can be used for processing a complex and deep profile, so that when the profile is designed, all profile characteristics such as flanging, hole flanging, positioning convex hulls and the like are designed on a drawing forming die for one-time processing, and only one-time working procedure-drawing thermal forming is carried out, and then a waste material area is cut by laser. Need not to design many sets of moulds, reduced the cover number of mould, saved the punching press number of times, reduced equipment, place, personnel input cost, greatly reduced manufacturing cost, improved the competitiveness in the market economy for the enterprise.
(2) The finished product of the invention has the advantages of 1200mm length, 1100mm width and 250mm depth, and the spread size of the plate before forming reaches 1600 multiplied by 1550 mm. And based on the method of the invention, the plate material used for aluminothermic forming does not require the use of materials subjected to tempering treatment in advance, and an additional supply chain link is not introduced, so that the raw material purchasing cost is saved, the time limit problem does not exist, and the centralized purchasing can be realized, thereby reducing the cost.
(3) By taking the aluminum alloy automobile body processed by the process of the invention as an example, the aluminum alloy material can save 40% of weight compared with steel material, and due to the good formability of the aluminum hot forming, the integration of a plurality of parts can be realized, the number of automobile assemblies is reduced, and the cost of the die and the stamping part is saved by over 20%. Because the stamping process comprises heating, quenching, cooling and pressure maintaining processes, the product has almost no springback, the accurate control of the dimensional precision of the product is realized for the first time, and the cost of repeatedly changing the die in the die developing, rectifying and reforming process is saved.
(4) The raw material used for aluminothermic forming and the process guarantee in the forming process ensure that the product can keep toughness after the production is finished, so that the yield strength of the product reaches 130Mpa, the tensile strength reaches 205Mpa, and the elongation after fracture can reach 30% at most. Therefore, the method can be widely applied to the fields of automobile manufacturing, aviation, rail transit and the like, and has wide market prospect.
Drawings
FIG. 1 is a process flow diagram of the present invention;
FIG. 2 is a graph of formability versus temperature as a sheet is heated.
Detailed Description
The invention will be further explained with reference to the drawings.
Example 1: referring to fig. 1 and 2, a one-time drawing hot forming method of a large-sized aluminum alloy plate comprises the following steps;
(1) selecting a plate material according to the material of a finished product, designing a process supplement surface according to the profile of the finished product, and designing a forming die surface of a drawing forming die according to the profile of the finished product and the process supplement surface, wherein the plate material is a heat-treatable strengthened aluminum alloy, the thickness of the plate material is 1-5 mm, and the depth of the profile is less than or equal to 250 mm;
(2) inputting a plate and a forming die surface into CAE software, setting an amplification factor of 1.001-1.0019 in the CAE software, and carrying out CAE simulation according to a one-time drawing thermal forming process;
(3) adjusting the forming die surface, the amplification coefficient and CAE built-in parameters until the forming die surface capable of processing qualified finished products is obtained and used as an optimal die surface, determining the amplification coefficient corresponding to the optimal die surface, amplifying the optimal die surface according to the optimal die surface and the amplification coefficient corresponding to the optimal die surface, and manufacturing a drawing forming die according to the amplified optimal die surface;
(4) arranging a heating furnace and a punching machine according to the processing sequence, and assembling a drawing forming die on a thermal forming punching machine;
(5) the method comprises the steps of obtaining a curve of the formability of a plate in a heating furnace along with the change of temperature, determining the temperature when the plate reaches the optimal formability, determining a temperature range as a forming temperature window by taking the temperature as a center, presetting the transfer time of the plate transferred from the heating furnace to a drawing forming die to be 19-35s, determining the target temperature of the heating furnace according to the forming temperature window and the transfer time, wherein the target temperature can ensure that the plate is transferred from the heating furnace to the drawing forming die to just reach the forming temperature window, and obtaining the shortest time for the heating furnace to heat the plate to the target temperature;
(6) heating the plate according to the shortest time and the target temperature, and transferring the plate to a drawing forming die in the transfer time;
(7) setting the stamping speed of a stamping machine tool to be 400-450mm/s, and completing stamping;
(8) maintaining the pressure for 40-50 s at 800-820 ton to obtain a drawing process part;
(9) and (5) cutting off the process supplement surface by laser to obtain a finished product.
Specifically, in step (1):
finished product molded surface: is the final profile characteristic retained by the finished product.
The process supplements the noodles: the product will not be retained in the end, but in order to create a good drawing condition for the cover, the window on the cover needs to be filled and leveled, the opening part is connected into a closed shape, the part with the flange needs to be smoothly transformed into a pressing surface which is beneficial to forming, the part without the flange needs to be supplemented with the pressing surface, and the added parts are called as process supplement parts. Pressing noodles: is an important component in the process supplement surface, namely the part outside the fillet radius of the concave die. The drawing blank is pressed on a female die pressing surface through a blank holder so as to ensure that the male die has good drawing effect on the drawing blank.
The finished product molded surface and the process supplement surface form a molding die surface, and the molding die surface comprises all molded surface characteristics of the finished product and molded surface characteristics corresponding to the flanging, the hole flanging and the positioning convex hulls. The method can realize the processing of large and deep-drawn parts only by one-time drawing forming process, so that more complicated profile characteristics can be completed at one time, a plurality of working procedures are not needed, and all the profile characteristics can be designed and completed at one time.
In the step (3), the adjustment of the molding die surface specifically comprises the following steps: adjusting the shape of the process supplement surface, the size of the plate, the shape of the plate, the height of the draw bead, the position of the draw bead or the ejection height of the blank holder, wherein the CAE built-in parameters comprise: transfer time, press speed, or temperature of the draw forming die. The CAE has many built-in parameters, and the content is only listed here but not limited thereto.
And (4) coating a lubricant on a lubricating area of the drawing forming die, specifically, setting a thinning threshold value, analyzing the qualified finished product in the step (3), and if the area of the qualified finished product is thinned and the thinning value is greater than or equal to the thinning threshold value, determining that the area is a thinning area, and determining that the position corresponding to the thinning area on the drawing forming die is the lubricating area. The purpose of this step is to avoid the defect that the thinning area is deformed, torn, wrinkled and the like during processing, and can effectively improve the qualification rate of products.
And (5) measuring the temperature by adopting temperature sensors, uniformly selecting a plurality of point positions on the plate, arranging the temperature sensors, and judging that the whole plate reaches a temperature value when each temperature sensor reaches the temperature value. The invention is suitable for different heating furnaces, and has different shapes and volumes of the heating furnaces or individual differences.
And a circulating cooling water channel is arranged on the drawing forming die, and the circulating cooling water channel is adopted to quench the drawing process part during pressure maintaining. Through the combined action of pressure maintaining and the circulating flow of cooling water inside the mold, the internal stress of the product can be eliminated, and the rebound of the product is reduced, so that the deformation and the size of the product are within the allowable range of quality. The circulating cooling water channel can be a single circulating cooling water channel or a double circulating cooling water channel.
Example 2: referring to fig. 1 and fig. 2, an aluminum alloy hot forming technology will become a development direction of future automobile parts, and on the basis of embodiment 1, we take processing an automobile door inner panel part as an example, and the specific method flow is as follows:
(1) selecting a plate material according to a finished product material, designing a process supplement surface according to a finished product profile, and designing a forming die surface of a drawing forming die according to the finished product profile and the process supplement surface, wherein the automobile door inner plate processed by the embodiment adopts a 6-series alloy aluminum plate, the size is 1593mm multiplied by 1520mm, the thickness is 1.2mm, the depth of the profile to be processed reaches 240mm, and the finished product profile not only comprises all profile characteristics of a finished product, but also comprises profile characteristics corresponding to flanging, hole flanging and positioning convex hulls which correspond to subsequent processes in the prior art;
(2) same as example 1, step (2);
(3) same as example 1, step (3);
(4) arranging a heating furnace and a punching machine according to the processing sequence, and assembling a drawing forming die on a thermal forming punching machine;
(5) the method comprises the steps of obtaining a curve of the formability of a plate in a heating furnace along with the change of temperature, determining the temperature when the plate reaches the optimal formability, and as can be seen from fig. 2, the formability of the 6-series alloy aluminum plate is rapidly increased along with the increase of the temperature in the early stage, the deformability of the 6-series alloy aluminum plate is hardly changed along with the increase of the temperature in the later stage, and the inflection point can be regarded as the temperature when the optimal formability is reached, and a forming temperature window is defined according to the temperature; in the embodiment, the forming temperature window of the 6-series alloy aluminum plate is 480-530 ℃;
presetting the transfer time of the plate from the heating furnace to the drawing forming die to be 19-35s, determining the target temperature of the heating furnace according to the forming temperature window and the transfer time, wherein the target temperature can ensure that the plate is transferred from the heating furnace to the drawing forming die and just reaches the forming temperature window, in the embodiment, the target temperature of the heating furnace is 450-580 ℃ according to multiple experiments of the actual field environment, and then obtaining the shortest time for the heating furnace to heat the plate to the target temperature;
(6) heating the plate according to the shortest time and the target temperature, and transferring the plate to a drawing forming die within 19-35s of the transfer time;
(7) setting the stamping speed of a stamping machine tool to be 400-450mm/s, and completing stamping; in the embodiment, the stroke of the slide block of the punching machine tool is 2050 mm, and even different parts can be punched in 4-5/s at the punching speed of 00-450mm/s, so that the product quality is ensured;
(8) maintaining the pressure for 40-50 s at 800-820 ton to obtain a drawing process part;
(9) and (5) cutting off the process supplement surface by laser to obtain a finished product.
According to the automobile door inner plate processed by the method, the product percent of pass reaches 95%, the yield strength reaches 130Mpa, the product tensile strength reaches 205Mpa, and the elongation after fracture can reach 30% at most and is far higher than the elongation after fracture of a cold-formed aluminum plate by 20%.
Example 3: referring to fig. 1 and 2, on the basis of example 2, the same automobile door inner panel part was manufactured, but 7-series alloy aluminum plate was selected. The forming temperature window of the 7-series aluminum alloy plate is 400-440 ℃, and the target temperature of the heating furnace is determined according to the temperature. Experimental tests show that the curve of the formability of the 7-series alloy aluminum plate in the heating furnace along with the change of temperature is closer to a parabola, and refer to fig. 2; therefore, the requirement on the target temperature of the heating furnace is more accurate, the heating process of the heating furnace can be divided into a front section and a rear section according to actual conditions in order to avoid the reduction of formability caused by overheating during actual heating, the front section is normally heated, and the target temperature in the heating furnace is accurately controlled by adopting a mode of gradually reducing the heating temperature when the target temperature is close to.
The rest is the same as in example 2. The other series of heat-treatable strengthened aluminum alloys were processed in the same manner as in examples 2 and 3.
The processing technology is applied to the processing of the inner plate part of the automobile door, the processing technology is simple, the size is large, the depth is large, the molded surface is complex, the blank of the technology in the automobile industry can be completely filled, and the development of the technology can be led for a long time. The method is not limited to the fields of the embodiment 1 to the embodiment 3, and can be applied to the parts which adopt the heat-treatable strengthened aluminum alloy and have the thickness of 1mm-5mm and the molded surface depth of less than or equal to 250mm in the aviation and rail transit industries.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention, and should not be taken as limiting the present invention, as the present invention is not limited to the aluminothermic forming press using the hard forming method with upper and lower pressing plates, and any modifications, equivalents and improvements made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (6)
1. A one-time drawing thermal forming method of a large-scale alloy aluminum plate is characterized in that: comprises the following steps;
(1) selecting a plate material according to the material of a finished product, designing a process supplement surface according to the profile of the finished product, and designing a forming die surface of a drawing forming die according to the profile of the finished product and the process supplement surface, wherein the plate material is heat-treatable strengthened aluminum alloy, the thickness of the plate material is 1-5 mm, and the depth of the profile is less than or equal to 250 mm;
(2) inputting the plate and the forming die surface into CAE software, setting an amplification factor of 1.001-1.0019 in the CAE software, and performing CAE simulation according to a one-time drawing thermal forming process;
(3) adjusting the forming die surface, the amplification coefficient and CAE built-in parameters until the forming die surface capable of processing qualified finished products is obtained and used as an optimal die surface, determining the amplification coefficient corresponding to the optimal die surface, amplifying the optimal die surface according to the optimal die surface and the amplification coefficient corresponding to the optimal die surface, and manufacturing a drawing forming die according to the amplified optimal die surface;
(4) arranging a heating furnace and a punching machine according to the processing sequence, and assembling a drawing forming die on a thermal forming punching machine;
(5) the method comprises the steps of obtaining a curve of the formability of a plate in a heating furnace along with the change of temperature, determining the temperature when the plate reaches the optimal formability, determining a temperature range as a forming temperature window by taking the temperature as a center, presetting the transfer time of the plate transferred from the heating furnace to a drawing forming die to be 19-35s, determining the target temperature of the heating furnace according to the forming temperature window and the transfer time, wherein the target temperature can ensure that the plate is transferred from the heating furnace to the drawing forming die to just reach the forming temperature window, and obtaining the shortest time for the heating furnace to heat the plate to the target temperature;
(6) heating the plate according to the shortest time and the target temperature, and transferring the plate to a drawing forming die in the transfer time;
(7) setting the stamping speed of a stamping machine tool to be 400-450mm/s, and completing stamping;
(8) maintaining the pressure for 40-50 s at 800-820 ton to obtain a drawing process part;
(9) and (5) cutting off the process supplement surface by laser to obtain a finished product.
2. The one-time drawing hot forming method of a large-sized aluminum alloy plate according to claim 1, characterized in that: in the step (1), the molding die surface comprises all the molded surface characteristics of the finished product and the molded surface characteristics corresponding to the flanging, the hole flanging and the positioning convex hull.
3. The one-time drawing hot forming method of a large-sized aluminum alloy plate according to claim 1, characterized in that: in the step (3), the adjustment of the molding die surface specifically comprises the following steps: adjusting the shape of the process supplement surface, the size of the plate, the shape of the plate, the height of a draw bead, the position of the draw bead or the ejection height of a blank holder, wherein the CAE built-in parameters comprise: transfer time, press speed, or draw forming die temperature.
4. The one-time drawing hot forming method of a large aluminum alloy plate according to claim 1, characterized in that: and (4) coating a lubricant on a lubricating area of the drawing forming die, specifically, setting a thinning threshold value, analyzing the qualified finished product in the step (3), and if the area of the qualified finished product is thinned and the thinning value is greater than or equal to the thinning threshold value, determining that the area is a thinning area, and determining that the position corresponding to the thinning area on the drawing forming die is the lubricating area.
5. The one-time drawing hot forming method of a large aluminum alloy plate according to claim 1, characterized in that: and (5) measuring the temperature by adopting temperature sensors, uniformly selecting a plurality of point positions on the sheet material to arrange the temperature sensors, and judging that the whole sheet material reaches a temperature value when each temperature sensor reaches the temperature value.
6. The one-time drawing hot forming method of a large-sized aluminum alloy plate according to claim 1, characterized in that: and a circulating cooling water channel is arranged on the drawing forming die, and the circulating cooling water channel is adopted to quench the drawing process part during pressure maintaining.
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