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基于M-K理論的6016鋁合金成形極限曲線預測

Prediction of forming limit curve of 6016 aluminum alloy based on M-K theory

  • 摘要: 近年來,為實現汽車車身輕量化,大量的鋁合金材料被用于汽車車身制造,由于6016鋁合金具有良好的烘烤性能,被大量使用.但是傳統的冷成形技術并不能成形復雜零件,因此熱沖壓-冷模具淬火成形技術被用到鋁合金的成形過程中,板材成形領域中一個重要的性能指標是成形極限.本論文使用理論預測和試驗兩種方法對6016鋁合金成形極限曲線進行了研究.首先,建立了考慮應變強化和應變速率強化的Fields-Bachofen本構方程,并將此本構方程引入到成形極限理論推導過程中;然后,基于M-K凹槽理論,對6016鋁合金成形極限曲線進行了理論預測,并且采用Nakazima試驗方法對預測結果進行了驗證.結果顯示,隨著初始厚度不均度的增加,預測曲線向縱坐標的正方向移動;通過實驗值和預測值的對比發現M-K凹槽理論對成形極限曲線的預測是可行的、準確的.

     

    Abstract: In recent years, due to the increasing demand for lightweight products in automotive industries to save energy and decrease CO2 gas emissions, many aluminum alloy materials are being used in cars. Due to its good baking performance, 6016 aluminum alloy is popular. However, traditional forming technology cannot produce complex parts. Furthermore, recent studies have focused on the hot stamping of aluminum alloy sheets and, in particular, of 6016 aluminum alloy sheets. It is well-known that sheet-metal formability is enhanced when the blanks are formed in hot temperatures. When this is done, the forming limit curve will rise. The forming limit of the material during the hot forming process is an important index and studying the forming limit of aluminum alloys at high temperature is of direct significance to production practices. In this paper, the forming limit curve of 6016 aluminum alloy was studied by theoretical prediction and experimentation. First, to evaluate the flow stress of a 6016 aluminum alloy sheet, the uniaxial hot tensile tests were conducted over a strain rate range of 0.01-1 s 1 and a temperature range of 400-500℃. Then, the Fields-Bachofen constitutive equation was established with considering strain hardening and strain rate enhancement, which matched well with the experimental measurements. Then this constitutive equation was introduced into the forming limit theory. Finally, based on the M-K groove theory, the forming limit curve of 6016 aluminum alloy was theoretically predicted, and the prediction results were validated by using the Nakazima test method. The comparison of the experimental and predicted values shows that the M-K groove theory is reasonable and accurate in predicting the forming limit curve. The effect of the initial inhomogeneity factor was analyzed on the forming limit curve. The results show that the prediction curve moves in the positive direction of the vertical coordinate, with an increase in the initial inhomogeneity factor. Also, the effect of the initial inhomogeneity factor on different strain paths differs, and the impact on the tension-tension strain states is greater than that on the tension-compression strain states.

     

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