6063铝合金触座精密成形工艺数值模拟及试验研究

    Numerical Simulation and Experimental Study on Precision Forming Process of 6063 Aluminum Alloy Contact Seat

    • 摘要: 为了研究6063铝合金触座精密成形工艺,利用Gleeble-1500D热模拟试验机对6063铝合金进行高温压缩试验,得到其在不同变形条件下的流变应力曲线,其流变应力随应变速率的增加而提高,随变形温度的升高而降低,合金具有正应变速率敏感性。将试验数据进行处理,经线性拟合得到其Arrhenius本构方程,其中热变形激活能为235.1548 kJ·mol-1。利用试验数据对其压缩热变形过程进行数值模拟分析,得到其不同应变下的临界损伤值,且临界损伤值与应变速率呈正相关。然后利用数值模拟软件对某型号6063铝合金触座的精密成形工艺进行了数值模拟分析,对影响成形质量的关键工艺参数进行正交试验优化,得到6063铝合金触座精密成形的优化工艺参数组合:成形温度为490℃、成形速度为20 mm/s、摩擦系数为0.3。分析了成形过程中工件的等效应力分布、模具应力分布,模具应力在H13热作模具钢许用应力范围内,不会对模具产生破坏。最后,进行了相应的工艺试验研究验证,试验得到的6063铝合金触座锻件充填饱满,后续机械加工后没有出现锻造缺陷,说明本文制定的6063铝合金触座的精密成形工艺是可行的,对该类零件的实际生产具有指导价值。

       

      Abstract: In order to study the precision forming process of 6063 aluminum alloy contact seat, Gleeble-1500D thermal simulation test machine was first used to conduct high-temperature compression experiments on 6063 aluminum alloy, and the rheological stress curves under different deformation conditions were obtained. The flow stress increases with the increase of strain rate and decreases with the increase of deformation temperature, indicating that the alloy has sensitivity to normal strain rate. The experimental data was processed and its Arrhenius constitutive equation was obtained through linear fitting, where the activation energy for thermal deformation is 235.1548 kJ·mol-1. Using experimental data to numerically simulate and analyze its compression thermal deformation process, the critical damage values under different strains were obtained, and the critical damage values are positively correlated with the strain rate. Then, numerical simulation software was used to analyze the precision forming process of a certain type of 6063 aluminum alloy contact seat. Orthogonal experiments were conducted to optimize the key process parameters that affect the forming quality. The optimized process parameter combination for precision forming of 6063 aluminum alloy contact seat was obtained as follows: forming temperature of 490 ℃, forming speed of 20 mm/s, and friction coefficient of 0.3. The equivalent stress distribution of the workpiece and the stress distribution of the mold during the forming process were analyzed. The mold stress is within the allowable stress range of H13 hot work mold steel and can not cause damage to the mold. Finally, corresponding process experiments were conducted to verify that the 6063 aluminum alloy contact seat forging obtained from the experiment is fully filled, and there are no forging defects after subsequent mechanical processing. This indicates that the precision forming process of the 6063 aluminum alloy contact seat developed in this research is feasible and has certain guiding value for the actual production of such parts.

       

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