Process Research And Design Of Warm Hydroforming System For Aluminum Alloy

In order to save energy,reduce costs and meet design requirements,the automobile industry,aerospace and other fields are in urgent demand for lightweight structure.Lightweight structure can be achieved through two ways,which are lightweight structure design and the use of lightweight materials.Tube hydroforming technology is a kind of flexible manufacturing technology that is to prepare hollow variable section light body components.Aluminum alloy is a kind of high quality and lightweight materials.Applied the tube hydroforming technology into aluminum alloy forming will take into account the two ways of the lightweight,and can improve the machining efficiency and the precision of forming of aluminum alloy.But the lower elongation rate of aluminum alloy at room temperature hinders it formed into complex workpiece.In order to solve this problem,aluminum alloy material needs to be heated to a certain temperature,then forming it,which is called warm hydroforming.At present,although there are some universities and research institutions are carrying out this technology research in our country,the development of this technology is rather slow due to the study of this technology in China starting relatively late,and lack of theoretical basis and experimental conditions.As the basis of research on pipe forming technology warm hydraulic forming equipment has a direct influence on the forming effect of pipe,so the design and development of warm hydraulic forming system is the most important thing at present,This paper reviewed the relevant literatures and summarized the research status of warm,hydroforming teclenology at lhome and abroad.To the question ot different heating modes'influence on tube stock formation,which put forwards by foreign scholars,we propose the new method of heating the mould by the heat conducting oil,which can realize rapid heating and cooling of the mould,and it can also solve the previous problems that the mould can't be quickly partial cooled in the process of hot forming.We also have made the design and simulation of channel arrangement scheme,which provides the reference for the production of mould design.The formation and function of the warm hydraulic forming system are described in detail in this thesis.The influence of each part on the tube forming is analyzed in detail.At the same time,the key design parameters of tube hydroforming system and parameter selection criteria are also listed out,which provides a reference for the research and development of the system.The design requirements of the hydraulic system for the thermal hydroforming process are analyzed,and the key technology of the hydraulic system design is studied in this thesis.The complex system is simplified by dividing the entire hydraulic system into several parts to make particular description,which is easy to understand and also highlights the innovation of the main technology and design of each part of the system.The tensile and free bulging properties of the developed workpiece material are tested and simulated,and the load curve is optimized.