摘要
为解决某汽车排气尾管一体化成形中成形道次多的制造问题,提出了与传统压扁特征处对称结构(A型)设计思路不同的圆截面处对称结构(B型),并采用液力成形工艺对其进行成形,通过对比成形道次和零件质量,分析了两种对称结构工件成形的优缺点。研究发现,由于A型结构工件一道次成形时圆角处会出现裂纹,需采用多工步成形才能实现;而B型结构工件一道次成形效果良好;经多工步成形的A型结构工件和一道次成形的B型结构工件最大壁厚减薄率均小于25%。但是,与A型对称结构工件相比,B型对称结构工件圆角处壁厚减薄率更低,成形效果更好,并且模具数量由3套减少为1套。通过合理的零件结构设计,该结构打破了传统圆形截面端部密封的设计束缚,不仅有效降低了模具成本,还提高了生产效率,大幅提高了零件成形效果。
To solve the manufacturing problem of multiple forming passes in integrated forming of an automobile exhaust liner,the sym-metrical structure at the circular cross-section(B-type)was proposed which is different from the design idea of traditional symmetrical structure at the traditional flattening feature(A-type),which were formed by hydro-mechanical forming process.By comparing the form-ing passes and part quality,the advantages and disadvantages of the two kinds of symmetrical structures workpiece were analyzed.It is found that because of the cracks in the round corners of the A-type workpiece during the one-step forming,it is necessary to adopt multi-step forming to realize it.The B-type workpiece has good forming effect with one-step forming.The maximum wall thickness reduction rates of the A-type structure workpiece after multi-step forming and the B-type workpiece after one-step forming are both less than 25%.However,compared with the A-type symmetrical structure workpiece,the wall thickness reduction rate at the round corner of B-type work-piece is lower,and the forming effect is better.The number of mold of B-type structure is reduced from three sets to one set.Through the reasonable part structure design,the structure breaks the traditional circular section end seal design constraints,not only effectively re-duces the cost of the mold,but also improves the production efficiency,and greatly improves the part forming effect.
作者
解文龙
刘鑫
徐勇
黄新越
岳峰丽
张士宏
XIE Wen-ong;LIU Xin;XU Yong;HUANG Xin-yue;YUE Feng-i;ZHANG Shi-hong(Shi-changxu Innovation Center for Advanced Materials,Institute of Metal Research,Chinese Academy of Sciences,Shenyang 110016,China;School of Mechanical Engineering and Automation,University of Science&Technology Liaoning,Anshan 114051,China;Shenyang Duoyuan Mechanical&Electrical Equipment Co.,Ltd.,Shenyang 110000,China;College of Automobiles&Transportation,Shenyang Ligong University,Shenyang 110159,China)
出处
《塑性工程学报》
CAS
CSCD
北大核心
2024年第4期227-233,共7页
Journal of Plasticity Engineering
基金
沈阳市科技计划资助项目(22-301-1-10)。
关键词
液压成形
液力成形
大截面变化率
结构设计
hydroforming
hydro-mechanical forming
large cross-section change rate
structure design
