(1. 湘潭大學 機械工程學院，湘潭 411105； 2. 華中科技大學 材料成形與模具技術國家重點實驗室，武漢 430074； 3. 日本岐阜大學 機械系統(tǒng)工學科，岐阜 501-1193)
摘 要: 以鋁合金筒形件底部實心凸起成形為例，提出采用拉深-鐓擠板鍛造工藝成形中心實心凸起結構，結合有限元模擬技術及工藝實驗方法，比較傳統(tǒng)反擠壓工藝與板鍛造工藝成形實心凸起結構的異同。結果表明：當成形同一凸起高度時，板鍛造成形載荷比反擠壓成形載荷減小一倍左右。板鍛造成形過程中，底部分流面位置先內移后趨于穩(wěn)定；而在反擠壓成形過程中，底部分流面位置先趨于穩(wěn)定后外移。凸模與板料上表面的單面潤滑可有效防止底部縮孔缺陷。
關鍵字: 鋁合金板材；實心凸起；板鍛造；分流面；縮孔機制
（1. School of Mechanical Engineering, Xiangtan University, Xiangtan 411105, China; 2. State Key Laboratory of Materials Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China; 3. Department of Mechanical and Systems Engineering, Gifu University, Gifu501-1193, Japan）
Abstract:A new solid boss plate forging process named compression-drawing method was proposed to form the aluminum alloy sheet. The finite element method with DEFORM-2D and experiments were used to investigate the solid boss forming process. As a result, the forming load of back-extrusion is about two times higher than that of plate forging when the same height boss is acquired. During the solid boss forming, the location of separation flow surface first moves inner side and then remains stable as for plate forging, while it first remains stable and then moves outer side as for back extrusion. Besides, single lubrication between punch and upper side of workpiece can prevent the dimple defect.
Key words: aluminum alloy sheet; solid boss; plate forging; separation flow surface; dimple defect mechanism
