坯料夹持力和初始坯料尺寸对深拉工艺下由 5754-O 铝合金板材制成的油箱部件减薄问题的影响研究

Jidapa Leelaseat, Phiraphong Larpprasoetkun, Aekkapon Sunanta, A. Nakwattanaset, S. Suranuntchai
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引用次数: 0

摘要

深冲工艺是汽车制造中一种常见的钣金成型技术。深冲零件可能出现三种主要缺陷:撕裂、起皱和变薄。当减薄很难通过目视检查检测出来时,深冲零件就会发生变形。因此,本研究旨在解决在冷加工深冲工艺下,由厚度为 1.5 mm 的 AA5754-O 铝合金板材制成的油箱零件的减薄问题,而制造商要求的减薄上限为 20%。通过 PAM-STAMP 模拟软件使用有限元分析 (FEA) 对两个影响参数(即坯料夹持力和坯料初始尺寸)进行了研究和优化,验证的材料模型基于希尔 1948 各向异性屈服准则和斯威夫特硬化定律。上述模型中的机械参数来自单轴拉伸试验的结果。总之,液压垫的坯料夹持压力和坯料的初始尺寸都会单独或共同影响零件的减薄。尽管对这两个参数进行了优化,但仍无法持续达到所需的极限。
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Investigation on the Effect of Blank Holder Force and Initial Blank Size on the Thinning Problem of the Fuel Tank Part Made from Aluminum Alloy Sheet 5754-O under Deep Drawing Process
Deep drawing process is a common sheet metal forming technique in motor vehicle manufacturing. There are three primary defects that could be occur in deep-drawn parts: tearing, wrinkling, and thinning. When the thinning is difficulty detected by visual inspection. As a result, this study aims to address the thinning issue in a fuel tank part made from an aluminum alloy sheet AA5754-O 1.5 mm thick under cold working deep drawing process, while the manufacturer's desired upper limit for thinning is 20%. Two influential parameters viz. blank holder force and initial size of blank, were investigated and optimized by using Finite Element Analysis (FEA) through PAM-STAMP simulation software with the validated material model was based on Hill’s 1948 anisotropic yield criterion with Swift hardening law. The mechanical parameters in the mentioned model were derived from the results of uniaxial tensile tests. In conclusion, both the hydraulic cushion's blank holder pressure and the initial size of the blank were found to influence the thinning of the part, either individually or in combination. Despite optimizing both parameters, they were unable to consistently achieve the desired limit.
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