Viscous Pressure Forming Of Aluminum Alloy Box-Shaped Parts With A Prefabricated Hole

Based on the difficulty of forming aluminum alloy box-shaped parts with a hole at the bottom,and combine the advantages of viscous pressure forming method,a method for viscous pressure forming of aluminum alloy box-shaped parts with a hole at the bottom is proposed.The sheet with a prefabricated hole is used for forming to improve the state of stress and the forming process,and improve its forming performance.At the same time,mechanical analysis,finite element analysis and experimental verification of its forming process were performed to optimize the viscous pressure forming process of the aluminum alloy box-shaped part with a hole at the bottom,which provided a new way for forming such parts.Firstly,the forming mechanism of the box-shaped parts with a hole at the bottom is studied,the deformation area of the part is divided,and the mechanical analysis of the forming process in different regions is performed through mechanical analysis and formula deduction.The study of viscous pressure forming of aluminum alloy box-shaped parts with a hole provides a theoretical basis.Secondly,based on the theoretical analysis,the finite element software ANSYS / LS-DYNA is used to analyze the variables such as the shape and size of the prefabricated hole,and the wall thickness and Von Mises effective strain distribution of the sheets with different prefabricated hole shapes and sizes during forming are obtained.The finite element comparative analysis of preformed hole sheets with different degrees of complexity(the width to length ratios),and then the law of pressure forming of aluminum alloy box-shaped parts with a hole at the bottom is obtained.Finally,the viscous pressure forming of the aluminum alloy box-shaped parts with a hole at the bottom was experimentally verified.A reasonable sealing device was designed and tested by measuring the characteristic dimensions of box shaped parts with different prefabricated hole and different the width to length ratios,the accuracy of the finite element results and the feasibility of the proposed method were verified.