Study On Progressive Forming Law Of Punch Support For 1060 Aluminum Plate Round Table

Progressive forming process is a kind of metal sheet plastic forming technology which realizes the integration of CAD/CAM/CAE and three-dimensional intelligent rapid prototyping.The chief aim of this research is forming round table parts.Based on the ANSYS/LS-DYNA analysis platform,the finite element model of punch support progressive forming is constructed.The forming law of single pass and multi pass of punch support progressive forming of 1060 Aluminum plate round table parts is studied by using the method of numerical simulation and solid experiment,which has important guiding significance for the rapid manufacturing of round table parts and other rotating parts.In the study of single pass progressive forming of round table parts,when the height diameter ratio H/D of round table parts is 0.5 and 1.0 respectively,the uniform critical angle and limit angle of wall thickness corresponding to different round table diameter D and different original blank thickness t₀ are explored.The results show that the critical angle and limit angle decrease with the increase of round table diameter and increase with the increase of original blank thickness.Using multiple linear regression,the estimation formula of the critical angle of uniform wall thickness of round table parts with H/D=0.5 and 1.0 is obtained,which can provide a reference basis for the design of the maximum forming angle of the first pass path when the wall thickness distribution of round table parts is uniform in single pass forming and multi pass forming.The minimum wall thickness variation curve obtained in the study can meet the requirements of changeable wall thickness distribution and the judgment of critical angle and limit angle.In the research of multi pass progressive forming of large angle round table parts,the variable angle linear forming path scheme,equal height parallel forming path scheme and equal height variable angle forming path scheme of multi pass progressive forming of large angle round table parts are discussed.When forming large angle round table parts with height diameter ratio H/D of 0.5 and1.0,the optimal path schemes with different diameters,angles and pass times are discussed.The research results show that,The optimal path scheme of large angle round table with H/D of 0.5 is equal height parallel path,and the optimal path scheme of large angle round table with H/D of 1.0is equal height variable angle path.On this basis,the parameters of the selected multi pass progressive forming path scheme are optimized,and the reasonable number of forming passes of large angle round table parts with height diameter ratio H/D of 0.5 and 1.0 are obtained under different diameters and angles.The wall thickness distribution curves of large angle round table parts with forming H/D of 0.5 and 1.0 at different diameters,angles and original blank thickness are obtained.By analyzing the average wall thickness in the stable forming area.And the maximum relative deviation,the average wall thickness t of multi pass progressive forming of large angle circular table is obtained by multiple nonlinear regression.The rapid progressive forming of round table parts in a certain range is realized.