摘要
为了解决平底无铆连接技术中匙孔缺陷问题,提出了摩擦辅热平底铆压塑性连接工艺,针对2 mm厚5754铝合金板材开展了摩擦辅热平底铆压过程数值模拟和试验研究。首先,研究了铝合金板材摩擦辅热平底铆压过程中的材料流动行为和温度场分布,重点讨论了转速、摩擦加热时间和铆压速度对温度场分布、铆压力和成形效果的影响规律。然后,对比了摩擦辅热平底铆压工艺较平底无铆连接工艺在成形力和成形效果的提升能力,并根据摩擦热输入量对成形高度和互锁值的影响机制,确定了该工艺的合理工艺参数范围。最后,评估了有限元数值模型的准确性。结果表明:转速、摩擦加热时间和铆压速度是影响摩擦辅热平底铆压成形力和成形效果的关键因素,摩擦辅热平底铆压工艺较平底无铆连接工艺所需铆压成形力可降低67%,成形高度可提高11.1%,互锁值可提高42.1%;2 mm厚5754铝合金板材摩擦辅热平底铆压连接的最优转速范围为1000~1600 r·min^(-1),摩擦时间为10~15 s,铆压速度为0.2~1 mm·s^(-1);有限元分析结果与试验结果接近,比有限元数值模型可以有效预测摩擦辅热平底铆压连接成形过程。
To solve the keyhole defects in flat non-clinching joining technology,the friction assisted flat clinching(FFC)was proposed.The numerical simulation and test studies of FFC of 5754 aluminum alloy sheets with thickness of 2 mm were carried out.Firstly,the material flow behavior and temperature field distribution in FFC of aluminum alloy sheets were studied,and the influences of rotation speed,friction heating time and clinching speed on temperature field distribution,clinching force and forming characteristics were discussed emphatically.Then,the comparison between FFC and flat clinching was carried out in terms of the improvements in forming force and forming characteristics.The reasonable ranges of FFC process parameters were determined based on the influence of friction heat input on the forming height and interlocking dimension.Finally,the accuracy of finite element numerical model was assessed.The results show that rotation speed,friction heating time and clinching speed are the clinching key factors influencing the forming force and forming characteristics of FFC.Compared with the flat clinching,the clinching force during FFC is reduced by 67%while the forming height and interlocking dimension are improved by 11.1%and 42.1%,respectively.The optimal process parameters of 5754 aluminum alloy sheets with thickness of 2 mm are rotation speed of 1000-1600 r·min^(-1),friction time of 10-15 s and clinching speed of 0.2-1 mm·s^(-1).The finite element analysis results are close to the test results,and the finite element numerical model can effectively predict the FFC process.
作者
张鹏
张佳莹
赵升吨
张传伟
韩晓兰
蒋红
费亮瑜
ZHANG Peng;ZHANG Jia-ying;ZHAO Sheng-dun;ZHANG Chuan-wei;HAN Xiao-lan;JIANG Hong;FEI Liang-yu(School of Mechanical Engineering,Xi’an Jiaotong University,Xi’an 710049,China;College of Mechanical Engineering,Xi’an University of Science and Technology,Xi’an 710054,China;Mechanical Engineering College,Xi’an Shiyou University,Xi’an 710065,China)
出处
《塑性工程学报》
CAS
CSCD
北大核心
2022年第5期109-118,共10页
Journal of Plasticity Engineering
基金
国家自然科学基金联合基金项目(U1937203)
国家自然科学基金面上项目(51675414)
陕西省自然科学基础研究计划企业联合基金(2019JLP-06)。
关键词
摩擦辅热
平底铆压
塑性连接
工艺参数
数值模拟
friction assisted heating
flat clinching
plastic joining
process parameters
numerical simulation
