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铝合金覆盖件的应用是汽车轻量化的关键,但其制造难度较大。通过研究铝合金发动机罩外板的充液成形工艺过程,了解先进柔性技术在汽车领域应用的可行性。分析了工艺参数中液室压力与凸模行程匹配及压边力对板料减薄率的影响,从成形极限上判断零件无起皱、破裂现象的范围。获得最优的整形液室压力为12～20 MPa,压边力过小,板料不能充分塑性变形,压边力过大,板料易失稳破裂,最优的恒定压边力范围为1600～2000 k N。研究表明,采用板材充液成形柔性制造工艺,可降低噪音,无冲击线,且由于液室压力的作用,滑移线减小,可提高大型铝合金弱刚度板材的质量。
The application of aluminum alloy cover is the key to lightweight car, but its manufacturing is more difficult. By studying the process of liquid-filled forming process of the outer shell of the aluminum alloy hood, the feasibility of applying the advanced flexible technology in the automotive field is studied. The influence of liquid chamber pressure and punch stroke matching and blank holder force on the sheet thinning rate was analyzed in the process parameters, and the part without wrinkle and rupture was judged from the forming limit. The best plastic liquid chamber pressure of 12 ~ 20 MPa, blank holder force is too small, the sheet can not be fully plastic deformation, blank holder force is too large, the sheet easily destabilized rupture, the optimal constant blank holder force range of 1600 ~ 2000 kN. The research shows that the flexible manufacturing process of plate filling can reduce the noise and no impact line, and because of the pressure in the liquid chamber, the slip line can be reduced, which can improve the quality of the large rigid plate with aluminum alloy.