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Two-Stage Superplastic Forming of a V-Shaped Aluminum Sheet into a Trough with Deep and Irregular Contour

机译:V形铝板的两阶段超塑性成形为具有深且不规则轮廓的槽

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摘要

A sheet metal trough of aluminum alloy is manufactured by a two-stage gas forming process at 500℃. The product with sloped side walls is of ~1.2 m length and ~260 mm opening width, comprising two near-conical-shaped sinks at two ends. The depth of one sink apex is ~350 mm, which results in the depth/width ratio reaching 1.4. To form such a deep and irregular trough, a superplastic aluminum alloy 5083 initially bent into a V-shaped groove was prepared prior to the gas forming work. Within a single die, gas pressure is used to form the V-shaped blank into a preform die cavity prior to the pressure being reversed to form the sheet into the final component cavity. The preforming of the V blank creates a uniform length of line in order to improve the thickness profile of the final part. In this work, a preform has been designed to improve the forming of a complex component by providing a superior thickness profile as compared to a conventional single-stage forming cycle. However, a serious wrinkling situation was encountered, the cause of which has been analyzed using basic mechanics as well as numerical simulation.
机译:铝合金薄板槽是在500℃下通过两步气体成形工艺制造的。带有倾斜侧壁的产品长度为〜1.2 m,开口宽度为〜260 mm,在两端包括两个近圆锥形的水槽。 1个水槽顶点的深度为〜350mm,其深宽比达到1.4。为了形成这样的深且不规则的槽,在进行气体成形工作之前,准备了最初弯曲成V形槽的超塑性铝合金5083。在单个模具内,在将压力反转以将片材制成最终组件型腔之前,使用气压将V形坯料成型为预成型模具型腔。 V毛坯的预成型产生均匀的线长度,以改善最终零件的厚度轮廓。在这项工作中,已经设计了一种预成型坯,与传统的单阶段成型周期相比,该预成型坯通过提供优异的厚度轮廓来改善复杂部件的成型。然而,遇到了严重的起皱情况,其原因已使用基本力学和数值模拟进行了分析。

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