大型铝合金曲面零件电磁渐进成形线圈结构优化设计

发布时间：2018-05-19 14:20

本文选题：大型铝合金曲面零件 + 电磁渐进成形　；参考：《塑性工程学报》2015年06期

【摘要】：针对大型铝合金曲面零件电磁渐进成形工艺中板料不均匀变形的问题,基于ANSYS多物理场模块建立电磁场-结构场耦合模型,对成形过程进行数值模拟分析,研究电磁成形线圈结构参数对板料变形行为的影响,包括:线圈层数、线圈匝间距、线圈层间距、导线截面积和导线截面形状。研究表明,线圈层数增加,板料变形均匀性降低,而板料的变形量增大,多层线圈有利于提高线圈的强度和使用寿命;线圈匝间距与导线的宽度越接近,板料均匀变形效果越好;矩形导线截面的线圈相对圆形导线截面的线圈使板料变形更加均匀;线圈层间距和导线截面积对板料均匀变形影响不大,但是合理的结构参数可以提高线圈强度。提出了一种非等间距线圈结构,非等间距线圈产生的电磁场和电磁力是不均匀的,在板料半径1/3处受到的成形驱动力较大,而这种不均匀的变形力,进一步改善了电磁成形中板料的变形不均匀性,电磁成形平板线圈能与变形后的板料较好的贴合,使大型铝合金曲面零件电磁渐进成形能通过多次放电连续均匀塑性变形。通过实验验证了线圈结构优化设计的可靠性,实验结果与模拟结果基本一致,误差在12%以内。
[Abstract]:Aiming at the problem of uneven deformation of large aluminum alloy surface parts in electromagnetic progressive forming process, the coupling model of electromagnetic field structure field is established based on ANSYS multi physical field module. The numerical simulation analysis of forming process is carried out, and the influence of the structure parameters of the electromagnetic forming coil on the deformation behavior of the sheet material is studied, including the number of coil and the interturn of the coil. The distance, the spacing of the coil layer, the sectional area of the wire and the shape of the wire section. The study shows that the number of coil layers increases, the deformation uniformity of the sheet material decreases, the deformation of the sheet material increases, and the multistory coil is beneficial to improve the strength and service life of the coil; the closer the coil to the width of the wire is, the better the effect of the uniform deformation of the sheet material; the cross section of the rectangular wire. The coil relative to the circular conductor section makes the sheet deformation more uniform, the spacing of the coil and the cross section area have little influence on the uniform deformation of the sheet material, but the reasonable structural parameters can improve the strength of the coil. A kind of non equidistance coil structure is proposed. The electromagnetic and electromagnetic force produced by the non equidistant coils are uneven, and in the sheet material The forming driving force at the radius 1/3 is larger, and the uneven deformation force further improves the deformation inhomogeneity of the plate material in electromagnetic forming. The electromagnetic forming plate coil can fit well with the sheet after deformation, so that the electromagnetic progressive forming of large aluminum alloy surface parts can be continuously and uniformly plastic deformation through multiple discharge. The experimental results verify the reliability of the coil structure optimization design. The experimental results are basically consistent with the simulation results, and the error is less than 12%.
【作者单位】：华中科技大学材料科学与工程学院材料成形与模具技术国家重点实验室;
【基金】：国家自然科学基金资助项目(51575206) 国家重点基础研究发展计划资助项目(2011CB012802)
【分类号】：TG146.21

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