Effect of Forming Size on Sectional Deformation of Wave Stamping of 3003Al-H14 Micro Channel Flat Tube
The thin-walled flat tube with microchannels is an essential component for the construction of the constant tem-perature system in lithium-ion battery packs for new energy vehicles.The dimensions used in forming this component are critical factors that influence the deformation of the stamped section.An experimentally verified finite element model has been developed for the waveform stamping-springback of 3003Al-H14 thin-walled flat tubes with microchannels.This model was used to investigate the impact of forming dimen-sions such as section height,tube blank wall thickness,and relative bending radius scaling factors of the inner and outer surfaces on the section deformation ratio and average section deformation ratio.The research findings are as follows:①The section deformation ratio of the holes at the upper edge of the cross-section is generally larger,while the deforma-tion ratio of the remaining holes is relatively small and con-sistent in size.The section deformation ratio of the holes on the longitudinal section exhibits a distribution pattern with high peaks and valleys and low values in the middle section.② The section deformation ratio of the flat tube increases with the increase in section height.When the section height exceeds 4 mm,the ribs inside the flat tube significantly bend,leading to severe collapse of the cross-section.③ The average section deformation ratio of the flat tube decreases exponentially with in-creasing wall thickness.When the wall thickness equals 0.1 mm,all sections exhibit severe distortion,while when the wall thickness exceeds 0.3 mm,the maximum section distortion ratio decreases to 24.71%.④ A larger scaling factor of the rela-tive bending radius of the inner and outer surfaces results in a smaller actual bending degree of these surfaces and a smaller average section deformation ratio.This study has scientific significance and engineering value for the precise forming of thin-walled microchannel waveform flat tubes.
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