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Comparison of Advanced SPF Die Technologies in the Forming of a Production Panel

机译:生产面板形成中先进SPF模具技术的比较

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Superplastic forming (SPF) is a manufacturing process that can facilitate increased use of aluminum in automobile body structures. Despite considerable advantages with regards to formability and tooling costs, the process has been mostly limited to low volume production due to relatively long cycle times and the need to use specially processed sheet alloys. To address these issues, advanced processes such as two stage gas forming (TSGF) and hot draw mechanical pre-forming (HDMP) have been developed. Advantages of these processes have been demonstrated on the forming of a complex dash panel part. Final thickness distribution and forming time on this part manufactured with these two processes were compared to that of the same panel produced with conventional SPF. The HDMP technology which combines hot stamping with SPF was found to have the capability of forming a complex shaped component with a superior thickness profile and faster forming cycle than that formed with a conventional single stage or two stage forming cycle. Additionally, the HDMP process proved to be a robust process with a wide temperature window and allowed for the forming of lower-cost, non-spf aluminum, and magnesium sheet alloys. Finally, analysis of the post-form microstructure indicated that there was essentially no cavitation in panels formed with the HDMP process and that material with a coarse grain structure could be successfully formed.
机译:超塑性成形(SPF)是一种制造工艺,可以促进铝在汽车车身结构中的使用增加。尽管在可成形性和工具成本方面有相当大的优势,但由于周期时间相对较长,并且需要使用经过特殊处理的板材合金,因此该方法主要限于小批量生产。为了解决这些问题,已经开发了先进的工艺,例如两阶段气体成型(TSGF)和热拉伸机械预成型(HDMP)。这些过程的优势已在复杂的仪表板零件的成型上得到证明。将这两种方法制造的零件的最终厚度分布和成型时间与使用传统SPF生产的同一块面板进行了比较。发现将热冲压与SPF结合使用的HDMP技术具有形成复杂形状的部件的能力,该部件具有比传统的单阶段或两阶段成型周期更好的厚度轮廓和更快的成型周期。此外,事实证明,HDMP工艺是一种坚固的工艺,具有宽的温度范围,可用于形成成本较低的非spf铝和镁薄板合金。最后,对后成形微观结构的分析表明,通过HDMP工艺形成的面板基本上没有气蚀现象,并且可以成功地形成具有粗糙晶粒结构的材料。

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