Research On Forming Process Of Aluminum Alloy Large High-Rib Square Box

As a lightweight structural material,aluminum alloy is widely used in vehicles,aerospace and other fields,reducing the weight of products under the premise of meeting mechanical performance requirements.With the improvement of performance requirements in the future,traditional large-scale component preparation methods,such as casting and welding,can not effectively improve the performance of components,extrusion deformation can effectively improve material properties,but because the plastic forming process of large components requires high load,how to prepare high-precision large components under low load will be a key problem.The large aluminum alloy square box with high ribs studied in this paper is based on its large cross-sectional area,extrusion deformation requires a large load,through step-by-step forming uniform load can effectively reduce the forming load,through the main stress method to obtain the square component upsetting,reverse extrusion,bottom shrinkage process deformation force calculation formula,at the same time through the DEFORM simulation software to simulate and optimize the forming process,and finally determined the following three sets of process routes,process one: free forging-upsetting-primary anti-extrusion-bottom cutting-secondary reverse extrusion-bottom shrinkage;Process 2: free forging-upsetting-square punch pre-deformation-primary anti-extrusion-bottom cutting-secondary reverse extrusion-bottom shrinkage;Process 3: Free forging-upsetting-primary reverse extrusion-cutting round bottom-secondary reverse extrusion.Through simulation and test verification,process 1 can control the thickness of the bottom,but the folding phenomenon may occur during the bottom shrinkage process,and the load required for the forming of the bottom round mouth is large;Process 2 also realizes the forming of the box,but the process operation is complicated,and the temperature of the blank drops rapidly during the extrusion process,which can be used as a backup scheme for Process 1;Process three bottom round hole by the bottom of the bottom to realize,in the bottom cutting process using mandrels,hollow lower pad as the bottom cutting mold,played a mold multiple role effect,but in the secondary reverse extrusion process,the bottom stress of the blank will be a small degree of mandrel jacking,when the mandrel and the punch contact due to the large contact area can not continue to press,can not effectively control the bottom thickness,more suitable for the bottom very thin box forming process.By exploring the plastic forming process of large components,this study can effectively improve the performance of large components,meet the mechanical properties of components required for the development of various fields,promote the rapid development of various industries,and consolidate the foundation of plastic forming process,and strive to achieve the development goals of low loss,short process and high precision of box forming process.