Design and Optimization of the Whole Hydro-mechanical Forming Process of Aluminum Alloy Profile-shaped Tube with Large Cross-section Change Rate
To solve the difficulty of forming a hollow member with a large cross-section change rate,the work aims to form the hollow member with hydro-mechanical forming method and optimize the production process.Firstly,the A-type structure and B-type structure of the target part were designed by two different symmetrical modes of flattening section symmetry and circular section symmetry.The forming characteristics of the two different structures under the same loading path were com-pared by finite element simulation.The A-type structure with better forming effect was selected to study the forming process and the forming zoning diagram of the A-type structure was established.Then,the orthogonal test design was carried out according to the forming partition diagram.Under the same loading path,the maximum thinning rate of the target part formed by A-type structure was obviously smaller than that of B-type structure,and the tendency of folding or wrinkling was easy to appear at the flattening feature of B-type structure,while the wall thickness distribution was more uniform at the flattening feature of A-type structure,and the forming effect of A-type structure was better than that of B-type structure.The optimized process parameters were as follows:the pressing pressure of 2 MPa,the initial pressure of 7 MPa,the forming pressure of 15 MPa,the axial feed of 13 mm,and the maximum thinning rate of the formed parts of 15.9％.The results of the orthogonal forming test guided by the forming zone diagram meet the design requirements.The establishment of the forming zone diagram has a guiding role in the design of the forming test.The optimized process parameters are used to obtain good test results,which can provide guidance for industrial production.
large cross-section change ratehydro-mechanical forming of tubeorthogonal teststructure designprocess optimization
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