CN112872270A - Semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy U-shaped parts and using method thereof - Google Patents
Semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy U-shaped parts and using method thereof Download PDFInfo
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- 239000007787 solid Substances 0.000 title claims abstract description 125
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 57
- 239000002131 composite material Substances 0.000 title claims abstract description 35
- 238000000034 method Methods 0.000 title claims abstract description 35
- 230000007704 transition Effects 0.000 claims abstract description 11
- 238000010438 heat treatment Methods 0.000 claims description 33
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 16
- 239000002994 raw material Substances 0.000 claims description 12
- 239000007788 liquid Substances 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 230000032683 aging Effects 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 4
- 238000005520 cutting process Methods 0.000 claims description 4
- 229910002804 graphite Inorganic materials 0.000 claims description 4
- 239000010439 graphite Substances 0.000 claims description 4
- 210000001624 hip Anatomy 0.000 claims description 4
- 238000010791 quenching Methods 0.000 claims description 4
- 230000000171 quenching effect Effects 0.000 claims description 4
- 230000005855 radiation Effects 0.000 claims description 4
- 239000007921 spray Substances 0.000 claims description 4
- 238000001125 extrusion Methods 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 238000005204 segregation Methods 0.000 abstract description 2
- 238000010586 diagram Methods 0.000 description 8
- 238000005242 forging Methods 0.000 description 5
- 238000005266 casting Methods 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 230000009974 thixotropic effect Effects 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000000113 differential scanning calorimetry Methods 0.000 description 2
- 239000007791 liquid phase Substances 0.000 description 2
- 238000010099 solid forming Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 210000001787 dendrite Anatomy 0.000 description 1
- 238000001192 hot extrusion Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
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Abstract
A semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy U-shaped parts and a using method thereof relate to an aluminum alloy semi-solid thixotropic-solid plastic deformation composite forming device and a using method thereof. The invention aims to solve the technical problems that liquid-solid segregation is easy to cause in the existing semi-solid thixoforming and the mechanical property of a formed piece is difficult to further improve. The problem that the male die is easy to adhere to the blank and the formed part is difficult to eject is solved by setting reasonable fit clearance, roughness, draft angle, transition arc and the like among all parts of the die, and the mechanical property of the formed part is improved to a greater extent by controlling the die temperature, the blank temperature and the descending speed of the upper die to realize the first thixotropy and then the second plastic deformation. According to the invention, by means of semisolid thixotropic-solid plastic deformation composite forming and by means of laminar filling characteristics of semisolid blanks, forming flow of large-deformation and thin-wall parts is completed, and mechanical properties of a formed part are further improved by means of solid plastic deformation.
Description
Technical Field
The invention relates to an aluminum alloy semi-solid thixotropic-solid plastic deformation composite forming device and a using method thereof.
Background
The traditional casting process utilizes the liquidity of liquid metal to fill a cavity, so that parts with complex shapes can be prepared, but the mechanical properties of formed parts are poor due to casting defects such as shrinkage porosity and shrinkage cavity. The forging technology can solve the problem of insufficient mechanical properties of a cast product, but for a product with large deformation or a complex shape, the product is easy to be filled insufficiently, so that multiple processes are often needed for completion. Semi-solid forming is a near-net-shape forming technique that combines the advantages of casting and forging. Compared with the coarse dendrites generated in the casting process, the structure of the semi-solid forming part is more compact, so that the mechanical property is better, but the structure is still lower than that of a forged piece. Compared with forging, the semi-solid process has high material utilization rate, and the size or the shape of a formed part is less limited due to the lubricating effect of a liquid phase.
The semi-solid technology mainly comprises blank preparation and subsequent forming. Firstly, heating the hot forging state aluminum alloy to a position between solid-liquid lines to prepare a spherical solid-phase crystal grain and liquid-phase coexisting structure with thixotropic property. According to the high and low solid fraction of the blank, the method can be divided into thixoforming and rheoforming. The blank used for thixoforming has high viscosity and can be clamped, thereby simplifying the forming process and being easier to realize automation.
In order to further improve the quality of the thixotropic product, the temperature of the blank, the temperature of the die, the descending speed of the upper die and the like are controlled, so that the temperature is higher in the early stage of forming, and the shear thinning characteristic of the semi-solid blank is beneficial to mold filling; semi-solid thixotropy and solid plastic deformation coexist in different areas of the middle-term blank; the temperature of the blank is reduced below the solidus line in the later period, the blank is converted into plastic forming, and the mechanical property of the refined recrystallized microstructure is improved. Therefore, the integrated device can efficiently prepare products meeting shape requirements and having excellent mechanical properties. In addition, the problems of easy adhesion in the return stroke of the upper die and poor ejection of formed parts are solved by setting reasonable fit clearance, roughness, draft and transition circular arc among all parts of the die.
Disclosure of Invention
The invention provides a semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy odd-shaped parts and a using method thereof, aiming at solving the technical problems that liquid-solid segregation is easily caused in the existing semi-solid thixotropic forming and the mechanical property of a formed part is difficult to further improve.
The semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy U-shaped part comprises an upper die 1, a lower die 2 and an ejector rod 3;
the upper die 1 consists of a connecting structure 1-1, a middle structure 1-2 and a bottom structure 1-3; the connecting structure 1-1, the middle structure 1-2 and the lower structure 1-3 are fixed into an integral structure from top to bottom; the connecting structure 1-1 is formed by arranging two concentric cylinders up and down; the side wall of the middle structure 1-2 consists of a back surface, two opposite side surfaces and three front surfaces, and the six surfaces are vertical to the lower surface of the connecting structure 1-1; the bottom structure 1-3 is a T-shaped structure, the side wall of the upper part 1-3-1 of the T-shaped structure consists of a back face, two opposite side faces and three front faces, and the draft angles of the drawing dies of the six faces are all 1.5 degrees; the side wall of the lower part 1-3-2 of the T-shaped structure consists of a back face, two opposite side faces and a front face, and the draft angles of the four faces are all 1.5 degrees; two corners in front of the contact part of the upper part 1-3-1 and the lower part 1-3-2 are respectively provided with a triangular prism notch 1-4, and two edges of the bottom surface of the lower part 1-3-2 are transition arcs of R3 mm; the roughness of all the contact surfaces of the upper die 1 and the blank is Ra0.8;
the lower die 2 is composed of 4 stepped cavity structures, specifically two main body cavity parts 2-1, a first rectangular cavity 2-2 and a second rectangular cavity 2-3 which are contacted with parts; the outer wall of the lower die 2 is in a round table structure, the upper surface of the lower die is a big circle, and the lower surface of the lower die is a small circle; all inner walls of a main body cavity part 2-1 of the lower die 2 are inclined at 1.5 degrees, the shape of the inner walls is matched with that of a bottom structure 1-3 of the upper die 1, and the roughness of the surface contacted with a part is Ra1.6; the first rectangular cavity 2-2 and the second rectangular cavity 2-3 are matched with the ejector rod 3; the length, width and height of the first rectangular cavity 2-2 are 76mm, 63mm and 48mm respectively; the length, width and height of the second rectangular cavity 2-3 are 57mm, 44mm and 95mm respectively;
the ejector rod 3 consists of a large-end rod head 3-1 and a small-end rod body 3-2; the big end rod head 3-1 is matched with the first rectangular cavity 2-2 of the lower die 2, and the top surface of the big end rod head is aligned with the lower surface of the main body cavity part 2-1; a concave cavity enclosed by the big end rod head 3-1 and the main body cavity part 2-1 is contacted with the outer convex surface of the part; the small-end rod body 3-2 penetrates through the second rectangular cavity 2-3; the bottom of the big end rod head 3-1 of the ejector rod 3 is of an isosceles trapezoid structure 3-1-1, the slopes of four waists are all 60 degrees, and the area of the lower bottom surface is small; the roughness of the upper surface of the big end rod head 3-1 is Ra1.6;
the unilateral fit clearance of the upper die 1 and the lower die 2 is 0.18mm, and the unilateral fit clearance of the lower die 2 and the ejector rod 3 is 0.2 mm.
The use method of the semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy U-shaped part comprises the following steps:
the method comprises the following steps: cutting a hot-extruded 6A02 aluminum alloy bar into a rectangular blank according to 1.08-1.2 times of the volume of the designed asymmetric inverted-V-shaped part, wherein the long edge adopts a transition arc of R2 mm;
step two: the ejector rod 3 penetrates through the cavity part of the lower die 2 and penetrates out of the through hole in the middle of the lower die plate; closing the upper die 1 and the lower die 2; the lower die 2 and the upper die 1 are both connected with a hydraulic press;
step three: heating a semi-solid thixotropic-solid plastic deformation composite forming device of a 6A02 aluminum alloy odd-shaped part to 120-165 ℃, driving an upper die 1 to move upwards by a hydraulic press, and uniformly spraying water-based graphite liquid on a part cavity formed by the outer surface of the upper die 1, the inner surface of a lower die 2 and a large-end rod head 3-1 by a spray gun;
step four: descending the upper die 1 into the lower die 2 by 35mm, heating to enable the temperature of the lower die 2 to be 370-420 ℃, maintaining the temperature of the upper die 1 at 310-360 ℃ under the action of heat radiation of the lower die 2, and preserving heat for 1 hour; simultaneously, heating a cuboid aluminum alloy raw material to a semi-solid temperature in a resistance furnace; determining the semi-solid temperature interval to 584-664 ℃ according to Differential Scanning Calorimetry (DSC), setting the heating temperature to 590-650 ℃, and keeping the temperature for 20-45 min to prepare a semi-solid blank;
step five: the hydraulic press drives the upper die 1 to move upwards by 200mm to 350mm, the semi-solid blank heated in the resistance furnace is rapidly clamped to the middle position of a cavity formed by the lower die 2 and the ejector rod 3 by using the blank transfer device, and a gap of 10mm to 15mm is reserved between the side surface of the blank and the side surface of the cavity;
step six: the upper die 1 descends along with the hydraulic machine at the descending speed of 5-15 mm/s, and then is matched with the lower die 2 to implement a semi-solid thixotropic-solid plastic deformation composite forming process, wherein the pressure of the hydraulic machine is maintained at 280-400 MPa in the process, and the pressure is maintained for 40-50 s;
step seven: the hydraulic press drives the upper die 1 to move up by 280-350 mm, room-temperature water is poured onto a formed piece, and after the temperature is reduced to room temperature, an ejection cylinder of the hydraulic press pushes an ejector rod 3 to eject a part out of a die cavity;
step eight: and heating the resistance furnace to 520 ℃, putting the asymmetric inverted-V-shaped formed part into the furnace, preserving heat for 25min, performing solution treatment, performing water quenching, heating the resistance furnace to 160 ℃, putting the water quenched asymmetric inverted-V-shaped part into the furnace, preserving heat for 11h, performing aging treatment, and then performing air cooling to obtain the 6A02 aluminum alloy asymmetric inverted-V-shaped part.
The invention has the beneficial effects that:
1. according to the method provided by the invention, the blank temperature, the die temperature and the descending speed of the upper die are controlled, so that the segmented sequence near-net forming is carried out according to the thixotropy-first and then the plastic forging, and the large-deformation thin-wall part with high performance and complete filling is prepared at one time and low cost;
2. in the method provided by the invention, only a resistance furnace is used for preparing the semi-solid blank, the requirement on the environment is low, the hot extrusion state bar is directly heated under the air condition, and the semi-solid blank is efficiently prepared; the semi-solid blank consists of spherical solid particles with the diameter of about 95 mu m and liquid surrounding the spherical solid particles, and completely meets the subsequent forming requirement;
3. according to the invention, through reasonably designing the bottom surface transition arc of the upper die 1, the fit clearance between the lower die 2 and the upper die 1 and the roughness and the draft of the upper die 1, the blank is prevented from being adhered when the upper die 1 returns; the drawing inclination of the lower die 2, the roughness of the top surface of the cavity part 2-1 of the main body of the lower die 2 and the ejector rod 3, the fit clearance between the lower die 2 and the ejector rod 3 and the inclined surface of the isosceles trapezoid structure 3-1-1 of the ejector rod 3 are designed to facilitate the demoulding and ejection of parts;
4. according to the invention, through semi-solid thixotropic-solid plastic deformation composite forming, not only is the forming of parts with complex shapes realized, but also the problem of improving the mechanical property of formed parts is solved; by means of laminar filling characteristics of the semi-solid blank, forming flow of complex shapes is completed, and mechanical properties of a formed piece are further improved by means of solid plastic deformation.
Drawings
FIG. 1 is a schematic cross-sectional view of a semi-solid thixotropic-solid flow-deformation composite forming device for a 6A02 aluminum alloy I-shaped part according to a first embodiment;
FIG. 2 is a horizontal cross-sectional view of the middle structure 1-2 of FIG. 1;
FIG. 3 is a schematic view of an upper mold 1 according to a first embodiment;
FIG. 4 is an enlarged partial view of triangular prism indentations 1-4 of FIG. 3;
fig. 5 is a schematic view of a lower die 2 according to the first embodiment;
fig. 6 is a schematic view of the upper stem 3 according to the first embodiment;
FIG. 7 is a top view of a test-as-formed 6A02 aluminum alloy asymmetric inverted T-shaped part;
FIG. 8 is a bottom view of a test-as-formed 6A02 aluminum alloy asymmetrical inverted T-shaped part;
FIG. 9 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, wherein the heating temperature is set to 610 ℃, and the temperature is kept for 30min to prepare a semi-solid state blank;
FIG. 10 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, wherein the heating temperature is set to 620 ℃, and the temperature is kept for 35min to prepare a semi-solid state blank;
FIG. 11 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, wherein the heating temperature is set to 635 ℃, and the temperature is kept for 35min to prepare a semi-solid state blank;
FIG. 12 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, the heating temperature is set to 645 ℃, and the temperature is maintained for 40min to prepare a semi-solid state blank;
FIG. 13 is a first simulated temperature field during the forming of trial one;
FIG. 14 is a second simulated temperature field during forming of trial one;
FIG. 15 is a third simulated temperature field during the forming of trial one;
FIG. 16 is a fourth simulated temperature field during the forming of trial one;
FIG. 17 is a fifth simulated temperature field during the forming of trial one;
fig. 18 is a sixth simulated temperature field during the forming of trial one.
Detailed Description
The first embodiment is as follows: the embodiment is a semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy U-shaped parts, which is shown in figures 1-6 and specifically comprises an upper die 1, a lower die 2 and a mandril 3;
the upper die 1 consists of a connecting structure 1-1, a middle structure 1-2 and a bottom structure 1-3; the connecting structure 1-1, the middle structure 1-2 and the lower structure 1-3 are fixed into an integral structure from top to bottom; the connecting structure 1-1 is formed by arranging two concentric cylinders up and down; the side wall of the middle structure 1-2 consists of a back surface, two opposite side surfaces and three front surfaces, and the six surfaces are vertical to the lower surface of the connecting structure 1-1; the bottom structure 1-3 is a T-shaped structure, the side wall of the upper part 1-3-1 of the T-shaped structure consists of a back face, two opposite side faces and three front faces, and the draft angles of the six faces are all 1.5 degrees; the side wall of the lower part 1-3-2 of the T-shaped structure consists of a back face, two opposite side faces and a front face, and the draft angles of the four faces are all 1.5 degrees; two corners in front of the contact part of the upper part 1-3-1 and the lower part 1-3-2 are respectively provided with a triangular prism notch 1-4, and two edges of the bottom surface of the lower part 1-3-2 are transition arcs of R3 mm; the roughness of all the contact surfaces of the upper die 1 and the blank is Ra0.8;
the lower die 2 is composed of 4 stepped cavity structures, specifically two main body cavity parts 2-1, a first rectangular cavity 2-2 and a second rectangular cavity 2-3 which are contacted with parts; the outer wall of the lower die 2 is in a round table structure, the upper surface of the lower die is a big circle, and the lower surface of the lower die is a small circle; all inner walls of a main body cavity part 2-1 of the lower die 2 are inclined at 1.5 degrees, the shape of the inner walls is matched with that of a bottom structure 1-3 of the upper die 1, and the roughness of the surface contacted with a part is Ra1.6; the first rectangular cavity 2-2 and the second rectangular cavity 2-3 are matched with the ejector rod 3; the length, width and height of the first rectangular cavity 2-2 are 76mm, 63mm and 48mm respectively; the length, width and height of the second rectangular cavity 2-3 are 57mm, 44mm and 95mm respectively;
the ejector rod 3 consists of a large-end rod head 3-1 and a small-end rod body 3-2; the big end rod head 3-1 is matched with the first rectangular cavity 2-2 of the lower die 2, and the top surface of the big end rod head is aligned with the lower surface of the main body cavity part 2-1; a concave cavity enclosed by the big end rod head 3-1 and the main body cavity part 2-1 is contacted with the outer convex surface of the part; the small-end rod body 3-2 penetrates through the second rectangular cavity 2-3; the bottom of the big end rod head 3-1 of the ejector rod 3 is of an isosceles trapezoid structure 3-1-1, the slopes of four waists are all 60 degrees, and the area of the lower bottom surface is small; the roughness of the upper surface of the big end rod head 3-1 is Ra1.6;
the unilateral fit clearance of the upper die 1 and the lower die 2 is 0.18mm, and the unilateral fit clearance of the lower die 2 and the ejector rod 3 is 0.2 mm.
The second embodiment is as follows: the first difference between the present embodiment and the specific embodiment is: the connecting structure 1-1 consists of two concentric circles, the radius and the height of the cylinder with the large upper part are respectively 118.5mm and 28mm, and the radius and the height of the cylinder with the small lower part are respectively 95.5mm and 53 mm. The rest is the same as the first embodiment.
The third concrete implementation mode: the present embodiment differs from the first or second embodiment in that: the height of the middle structure 1-2 is 66.5 mm. The others are the same as in the first or second embodiment.
The fourth concrete implementation mode: the difference between this embodiment mode and one of the first to third embodiment modes is: the height of the lower part 1-3-2 is 45 mm. The rest is the same as one of the first to third embodiments.
The fifth concrete implementation mode: the fourth difference between this embodiment and the specific embodiment is that: the height of the upper part 1-3-1 is 22 mm. The rest is the same as the fourth embodiment.
The sixth specific implementation mode: the fifth embodiment is different from the fifth embodiment in that: the outer wall of the lower die 2 is in a circular truncated cone structure, the radius of a large circle on the upper surface is 125mm, and the radius of a small circle on the lower surface is 110 mm. The rest is the same as the fifth embodiment.
The seventh embodiment: the sixth embodiment is different from the sixth embodiment in that: the length, the width and the height of the small-end rod body 3-2 are 46mm, 41mm and 270mm respectively. The rest is the same as the sixth embodiment.
The specific implementation mode is eight: the embodiment is a use method of a semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy parts with a shape like a Chinese character 'ji', and the use method is specifically carried out according to the following steps:
the method comprises the following steps: cutting a hot-extruded 6A02 aluminum alloy bar into a rectangular blank according to 1.08-1.2 times of the volume of the designed asymmetric inverted-V-shaped part, wherein the long edge adopts a transition arc of R2 mm;
step two: the ejector rod 3 penetrates through the cavity part of the lower die 2 and penetrates out of the through hole in the middle of the lower die plate; closing the upper die 1 and the lower die 2; the lower die 2 and the upper die 1 are both connected with a hydraulic press;
step three: heating a semi-solid thixotropic-solid plastic deformation composite forming device of a 6A02 aluminum alloy odd-shaped part to 120-165 ℃, driving an upper die 1 to move upwards by a hydraulic press, and uniformly spraying water-based graphite liquid on a part cavity formed by the outer surface of the upper die 1, the inner surface of a lower die 2 and a large-end rod head 3-1 by a spray gun;
step four: descending the upper die 1 into the lower die 2 by 35mm, heating to enable the temperature of the lower die 2 to be 370-420 ℃, maintaining the temperature of the upper die 1 at 310-360 ℃ under the action of heat radiation of the lower die 2, and preserving heat for 1 hour; simultaneously, heating a cuboid aluminum alloy raw material to a semi-solid temperature in a resistance furnace; determining the semi-solid temperature interval to 584-664 ℃ according to Differential Scanning Calorimetry (DSC), setting the heating temperature to 590-650 ℃, and keeping the temperature for 20-45 min to prepare a semi-solid blank;
step five: the hydraulic press drives the upper die 1 to move upwards by 200mm to 350mm, the semi-solid blank heated in the resistance furnace is rapidly clamped to the middle position of a cavity formed by the lower die 2 and the ejector rod 3 by using the blank transfer device, and a gap of 10mm to 15mm is reserved between the side surface of the blank and the side surface of the cavity;
step six: the upper die 1 descends along with the hydraulic machine at the descending speed of 5-15 mm/s, and then is matched with the lower die 2 to implement a semi-solid thixotropic-solid plastic deformation composite forming process, wherein the pressure of the hydraulic machine is maintained at 280-400 MPa in the process, and the pressure is maintained for 40-50 s;
step seven: the hydraulic press drives the upper die 1 to move up by 280-350 mm, room-temperature water is poured onto a formed piece, and after the temperature is reduced to room temperature, an ejection cylinder of the hydraulic press pushes an ejector rod 3 to eject a part out of a die cavity;
step eight: heating a resistance furnace to 520 ℃, putting the asymmetric inverted-V-shaped formed part into the furnace, preserving heat for 25min, performing solution treatment, performing water quenching, heating the resistance furnace to 160 ℃, putting the water quenched asymmetric inverted-V-shaped part into the furnace, preserving heat for 11h, performing aging treatment, and then performing air cooling to obtain the 6A02 aluminum alloy asymmetric inverted-V-shaped part.
The specific implementation method nine: the eighth embodiment is different from the eighth embodiment in that: the extrusion ratio of the hot extruded 6A02 aluminum alloy bar in the step one is 1: 8. The rest is the same as the embodiment eight.
The detailed implementation mode is ten: the present embodiment differs from the ninth embodiment in that: in the first step, the hot-extruded 6A02 aluminum alloy bar is cut into rectangular blanks according to 1.09 times of the volume of the designed asymmetric inverted V-shaped part. The rest is the same as in the ninth embodiment.
The invention was verified with the following tests:
test one: the test is a semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy U-shaped parts, which is shown in figures 1-6 and specifically comprises an upper die 1, a lower die 2 and an ejector rod 3;
the upper die 1 consists of a connecting structure 1-1, a middle structure 1-2 and a bottom structure 1-3; the connecting structure 1-1, the middle structure 1-2 and the lower structure 1-3 are fixed into an integral structure from top to bottom; the connecting structure 1-1 is formed by arranging two concentric cylinders up and down; the side wall of the middle structure 1-2 consists of a back surface, two opposite side surfaces and three front surfaces, and the six surfaces are vertical to the lower surface of the connecting structure 1-1; the bottom structure 1-3 is a T-shaped structure; the side wall of the upper part 1-3-1 of the T-shaped structure consists of a back face, two opposite side faces and three front faces, and the draft angles of the six faces are all 1.5 degrees; the side wall of the lower part 1-3-2 of the T-shaped structure consists of a back face, two opposite side faces and a front face, and the draft angles of the four faces are all 1.5 degrees; two corners in front of the contact part of the upper part 1-3-1 and the lower part 1-3-2 are respectively provided with a triangular prism notch 1-4, and two edges of the bottom surface of the lower part 1-3-2 are transition arcs of R3 mm; the roughness of all the contact surfaces of the upper die 1 and the blank is Ra0.8; the connecting structure 1-1 consists of two concentric circles, the radius and the height of a large cylinder at the upper part are respectively 118.5mm and 28mm, and the radius and the height of a small cylinder at the lower part are respectively 95.5mm and 53 mm; the height of the middle structure 1-2 is 66.5 mm; the height of the lower part 1-3-2 is 45 mm; the height of the upper part 1-3-1 is 22 mm;
the lower die 2 is composed of 4 stepped cavity structures, specifically two main body cavity parts 2-1, a first rectangular cavity 2-2 and a second rectangular cavity 2-3 which are contacted with parts; the outer wall of the lower die 2 is in a round table structure, the upper surface of the lower die is a big circle, and the lower surface of the lower die is a small circle; all inner walls of a main body cavity part 2-1 of the lower die 2 are inclined at 1.5 degrees, the shape of the inner walls is matched with that of a bottom structure 1-3 of the upper die 1, and the roughness of the surface contacted with a part is Ra1.6; the first rectangular cavity 2-2 and the second rectangular cavity 2-3 are matched with the ejector rod 3; the length, width and height of the first rectangular cavity 2-2 are 76mm, 63mm and 48mm respectively; the length, width and height of the second rectangular cavity 2-3 are 57mm, 44mm and 95mm respectively; the outer wall of the lower die 2 is in a circular truncated cone structure, the radius of a large circle on the upper surface is 125mm, and the radius of a small circle on the lower surface is 110 mm;
the ejector rod 3 consists of a large-end rod head 3-1 and a small-end rod body 3-2; the big end rod head 3-1 is matched with the first rectangular cavity 2-2 of the lower die 2, and the top surface of the big end rod head is aligned with the lower surface of the main body cavity part 2-1; a concave cavity enclosed by the big end rod head 3-1 and the main body cavity part 2-1 is contacted with the outer convex surface of the part; the small-end rod body 3-2 penetrates through the second rectangular cavity 2-3; the bottom of the big end rod head 3-1 of the ejector rod 3 is of an isosceles trapezoid structure 3-1-1, the slopes of four waists are all 60 degrees, and the area of the lower bottom surface is small; the roughness of the upper surface of the big end rod head 3-1 is Ra1.6; the length, the width and the height of the small-end rod body 3-2 are 46mm, 41mm and 270mm respectively;
the unilateral fit clearance of the upper die 1 and the lower die 2 is 0.18mm, and the unilateral fit clearance of the lower die 2 and the ejector rod 3 is 0.2 mm.
The using method of the semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy U-shaped part is carried out according to the following steps:
the method comprises the following steps: cutting a hot-extruded 6A02 aluminum alloy bar into a rectangular blank according to 1.09 times of the volume of the designed asymmetric inverted-V-shaped part, wherein the long edge is 71.6mm, the short edge is 52.4mm, the height is 45.2mm, and the long edge adopts a transition arc of R2 mm; the extrusion ratio of the hot extruded 6A02 aluminum alloy bar in the step one is 1: 8;
step two: the ejector rod 3 penetrates through the cavity part of the lower die 2 and penetrates out of the through hole in the middle of the lower die plate; closing the upper die 1 and the lower die 2; fixing an upper die 1 on the lower surface of an upper die plate, and connecting the upper die plate with a movable cross beam of a 5000kN hydraulic press; the lower die 2 is fixed on the upper surface of a lower die plate, and the lower die plate is connected with a fixed lower cross beam of a 5000kN hydraulic press;
step three: a fixed sleeve is arranged on the outer wall of the lower die 2, a heating pipe (both conventional technologies) is arranged in the fixed sleeve, a semi-solid thixotropic-solid plastic deformation composite forming device of a 6A02 aluminum alloy odd-shaped part is heated to 120-165 ℃, then a hydraulic press drives the upper die 1 to move upwards, and water-based graphite liquid is uniformly sprayed on a part cavity formed by the outer surface of the upper die 1, the inner surface of the lower die 2 and the large-end rod head 3-1 by a spray gun;
step four: descending the upper die 1 into the lower die 2 by 35mm, heating to enable the temperature of the lower die 2 to be 370-420 ℃, maintaining the temperature of the upper die 1 at 310-360 ℃ under the action of heat radiation of the lower die 2, and preserving heat for 1 hour; simultaneously, heating a cuboid aluminum alloy raw material to a semi-solid state temperature in a resistance furnace, setting the heating temperature to be 590-650 ℃, and preserving the heat for 20-45 min to prepare a semi-solid state blank;
step five: the hydraulic press drives the upper die 1 to move upwards by 200mm to 350mm, the semi-solid blank heated in the resistance furnace is rapidly clamped to the middle position of a cavity formed by the lower die 2 and the ejector rod 3 by using the blank transfer device, and a gap of 10mm to 15mm is reserved between the side surface of the blank and the side surface of the cavity;
step six: the upper die 1 descends along with the hydraulic machine at the descending speed of 5-15 mm/s, and then is matched with the lower die 2 to implement a semi-solid thixotropic-solid plastic deformation composite forming process, wherein the pressure of the hydraulic machine is maintained at 280-400 MPa in the process, and the pressure is maintained for 40-50 s;
step seven: the hydraulic press drives the upper die 1 to move up by 280-350 mm, room-temperature water is poured onto a formed piece, and after the temperature is reduced to room temperature, an ejection cylinder of the hydraulic press pushes an ejector rod 3 to eject a part out of a die cavity;
step eight: heating a resistance furnace to 520 ℃, putting the asymmetric inverted-V-shaped formed part into the furnace, preserving heat for 25min, performing solution treatment, performing water quenching, heating the resistance furnace to 160 ℃, putting the water quenched asymmetric inverted-V-shaped part into the furnace, preserving heat for 11h, performing aging treatment, and then performing air cooling to obtain the 6A02 aluminum alloy asymmetric inverted-V-shaped part.
FIG. 9 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, wherein the heating temperature is set to 610 ℃, and the temperature is kept for 30min to prepare a semi-solid state blank;
FIG. 10 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, wherein the heating temperature is set to 620 ℃, and the temperature is kept for 35min to prepare a semi-solid state blank;
FIG. 11 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, wherein the heating temperature is set to 635 ℃, and the temperature is kept for 35min to prepare a semi-solid state blank;
FIG. 12 is a microscopic morphology diagram of a cuboid aluminum alloy raw material heated to a semi-solid state temperature in a resistance furnace in the fourth step, the heating temperature is set to 645 ℃, and the temperature is maintained for 40min to prepare a semi-solid state blank;
from fig. 9-12, it can be seen that the semi-solid billet is composed of spherical solid particles with a diameter of about 95 μm and liquid surrounding the spherical solid particles, and fully meets the requirements of subsequent forming.
Fig. 13-18 are simulated temperature fields during the forming process of test one, with the key parameters set as follows:
the descending speed of the upper die 1 is 8 mm/s;
the heat transfer coefficients of the lower die 2 and the blank and the upper die 1 and the blank are both 11N/s/mm/DEG C;
the friction coefficients of the upper die 1 and the blank and the lower die 2 and the blank are both 0.3;
the initial temperature of the upper die 1 is 370 ℃, the initial temperature of the lower die 2 is 410 ℃, and the initial temperature of the blank is 640 ℃;
in the initial pressing-down stage of the upper die 1, the temperature of each part of the blank is greater than 584 ℃ of the solidus line, and the blank is in the thixoforming stage;
the temperature is reduced along with the contact heat exchange of the blank with the upper die 2 and the lower die 2, the temperature of partial area is reduced to be below a solidus line, and at the moment, semi-solid thixotropy and solid plastic deformation coexist;
when the upper die further descends, all areas of the blank are solid, the deformation mode is completely converted into plastic deformation, and the sequential formation of semi-solid thixotropy and solid plastic deformation is realized;
when the forming is finished, the lowest temperature value of the formed piece is 476 ℃, and the highest temperature value is 551 ℃.
Claims (10)
1. A semi-solid thixotropic-solid plastic deformation composite forming device for 6A02 aluminum alloy odd-shaped parts is characterized in that the semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy odd-shaped parts is composed of an upper die (1), a lower die (2) and an ejector rod (3);
the upper die (1) consists of a connecting structure (1-1), a middle structure (1-2) and a bottom structure (1-3); the connecting structure (1-1), the middle structure (1-2) and the lower structure (1-3) are fixed into an integral structure from top to bottom; the connecting structure (1-1) is formed by arranging two concentric cylinders up and down; the side wall of the middle structure (1-2) consists of a back surface, two opposite side surfaces and three front surfaces, and the six surfaces are vertical to the lower surface of the connecting structure (1-1); the bottom structure (1-3) is a T-shaped structure, the side wall of the upper part (1-3-1) of the T-shaped structure consists of a back face, two opposite side faces and three front faces, and the draft angles of the six faces are all 1.5 degrees; the side wall of the lower part (1-3-2) of the T-shaped structure consists of a back surface, two opposite side surfaces and a front surface, and the draft angles of the four surfaces are all 1.5 degrees; two corners in front of the contact part of the upper part (1-3-1) and the lower part (1-3-2) are respectively provided with a triangular prism notch (1-4), and two edges of the bottom surface of the lower part (1-3-2) are transition arcs of R3 mm; the roughness of all the contact surfaces of the upper die (1) and the blank is Ra0.8;
the lower die (2) consists of 4 stepped cavity structures, specifically two main body cavity parts (2-1), a first rectangular cavity (2-2) and a second rectangular cavity (2-3) which are in contact with parts; the outer wall of the lower die (2) is in a round table structure, the upper surface of the lower die is a big circle, and the lower surface of the lower die is a small circle; all inner walls of a main body cavity part (2-1) of the lower die (2) are inclined at 1.5 degrees, the shape of the inner walls is matched with that of a bottom structure (1-3) of the upper die (1), and the roughness of the surface contacted with parts is Ra1.6; the first rectangular cavity (2-2) and the second rectangular cavity (2-3) are matched with the ejector rod (3); the length, the width and the height of the first rectangular cavity (2-2) are respectively 76mm, 63mm and 48 mm; the length, the width and the height of the second rectangular cavity (2-3) are 57mm, 44mm and 95mm respectively;
the ejector rod (3) consists of a large-end rod head (3-1) and a small-end rod body (3-2); the big end rod head (3-1) is matched with the first rectangular cavity (2-2) of the lower die (2), and the top surface of the big end rod head is aligned with the lower surface of the main body cavity part (2-1); a concave cavity enclosed by the big end rod head (3-1) and the main body cavity part (2-1) is contacted with the outer convex surface of the part; the small end rod body (3-2) penetrates through the second rectangular cavity (2-3); the bottom of the big end rod head (3-1) of the ejector rod (3) is of an isosceles trapezoid structure (3-1-1), the slopes of the four waists are all 60 degrees, and the area of the lower bottom surface is small; the roughness of the upper surface of the big end rod head (3-1) is Ra1.6;
the unilateral fit clearance of the upper die (1) and the lower die (2) is 0.18mm, and the unilateral fit clearance of the lower die (2) and the ejector rod (3) is 0.2 mm.
2. The semi-solid thixotropic-solid flow-deformation composite forming device for the 6A02 aluminum alloy part with the shape like the Chinese character 'ji' as claimed in claim 1, wherein the connecting structure (1-1) is composed of two concentric circles, the radius and height of the upper large cylinder are 118.5mm and 28mm respectively, and the radius and height of the lower small cylinder are 95.5mm and 53mm respectively.
3. The semi-solid thixotropic-solid flow-deformation composite forming device for the 6A02 aluminum alloy odd-shaped parts, according to claim 1, wherein the height of the middle structure (1-2) is 66.5 mm.
4. The semi-solid thixotropic-solid flow-deformation composite forming device for the 6A02 aluminum alloy odd-shaped parts according to claim 1, wherein the height of the lower part (1-3-2) is 45 mm.
5. The semi-solid thixotropic-solid flow-deformation composite forming device for the 6A02 aluminum alloy odd-shaped parts according to claim 1, wherein the height of the upper part (1-3-1) is 22 mm.
6. The semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy part with the shape like the Chinese character 'ji' according to claim 1, wherein the outer wall of the lower die (2) is in a circular truncated cone structure, the radius of the upper large circle is 125mm, and the radius of the lower small circle is 110 mm.
7. The semi-solid thixotropic-solid flow-deformation composite forming device for the 6A02 aluminum alloy odd-shaped parts, according to claim 1, wherein the length, width and height of the small end rod body (3-2) are 46mm, 41mm and 270mm respectively.
8. The use method of the semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy odd-shaped part as claimed in claim 1, wherein the use method of the semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy odd-shaped part is carried out according to the following steps:
the method comprises the following steps: cutting a hot-extruded 6A02 aluminum alloy bar into a rectangular blank according to 1.08-1.2 times of the volume of the designed asymmetric inverted-V-shaped part, wherein the long edge adopts a transition arc of R2 mm;
step two: the ejector rod (3) penetrates through the cavity part of the lower die (2) and penetrates out of the through hole in the middle of the lower die plate; closing the upper die (1) and the lower die (2); the lower die (2) and the upper die (1) are both connected with a hydraulic press;
step three: heating a semi-solid thixotropic-solid plastic deformation composite forming device of a 6A02 aluminum alloy odd-shaped part to 120-165 ℃, then driving an upper die (1) to move upwards by a hydraulic press, and uniformly spraying water-based graphite liquid on a part cavity formed by the outer surface of the upper die (1), the inner surface of a lower die (2) and a large-end rod head (3-1) by a spray gun;
step four: descending the upper die (1) to the lower die (2) for 35mm, heating to enable the temperature of the lower die (2) to be 370-420 ℃, maintaining the temperature of the upper die (1) at 310-360 ℃ under the action of heat radiation of the lower die (2), and preserving heat for 1 h; simultaneously, heating a cuboid aluminum alloy raw material to a semi-solid state temperature in a resistance furnace, setting the heating temperature to be 590-650 ℃, and preserving the heat for 20-45 min to prepare a semi-solid state blank;
step five: the hydraulic press drives the upper die (1) to move upwards by 200mm to 350mm, the semi-solid blank heated in the resistance furnace is rapidly clamped to the middle position of a cavity formed by the lower die (2) and the ejector rod (3) by using the blank transfer device, and a gap of 10mm to 15mm is reserved between the side surface of the blank and the side surface of the cavity;
step six: the upper die (1) descends along with the hydraulic machine at the descending speed of 5-15 mm/s, and then is matched with the lower die (2) to carry out a semi-solid thixotropic-solid plastic deformation composite forming process, wherein the pressure of the hydraulic machine is maintained at 280-400 MPa in the process, and the pressure is maintained for 40-50 s;
step seven: the hydraulic press drives the upper die (1) to move up by 280-350 mm, room-temperature water is poured onto a formed piece, and after the temperature is reduced to room temperature, an ejection cylinder of the hydraulic press pushes an ejector rod (3) to eject a part out of a die cavity;
step eight: heating a resistance furnace to 520 ℃, putting the asymmetric inverted-V-shaped formed part into the furnace, preserving heat for 25min, performing solution treatment, performing water quenching, heating the resistance furnace to 160 ℃, putting the water quenched asymmetric inverted-V-shaped part into the furnace, preserving heat for 11h, performing aging treatment, and then performing air cooling to obtain the 6A02 aluminum alloy asymmetric inverted-V-shaped part.
9. The use method of the semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy geometric-shaped part as claimed in claim 8, wherein the extrusion ratio of the hot extruded 6A02 aluminum alloy bar in the step one is 1: 8.
10. The use method of the semi-solid thixotropic-solid plastic deformation composite forming device for the 6A02 aluminum alloy odd-shaped parts, as claimed in claim 8, wherein in the step one, the hot extruded 6A02 aluminum alloy bar is cut into rectangular billets according to 1.09 times of the volume of the designed asymmetric odd-shaped parts.
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| CN117855769A (en) * | 2024-03-06 | 2024-04-09 | 厦门海辰储能科技股份有限公司 | Lower plastic, end cover assembly, energy storage device and electric equipment |
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