Research On Deep Drawing Process And Quality Control Of 3104 Aluminum Alloy Thin-Walled High Rectangular Cup

With the development of forming technology,a new type of high rectangular food cans appeared in the field of food packaging.The new type of high rectangular food cans takes 3104 aluminum alloy sheet as the material,the body and the bottom of the can are integrally formed,which can attract more attention of consumers in the market.The high rectangular food can has the following features: 1)the material is aluminum alloy sheet as low as 0.3mm,the side wall thickness of the formed high rectangular cups is small,and the thin-walled features are evident;2)The length difference of the long and short sides of the high rectangle cups is evident,the relative height is high,and the high rectangular shape features are obvious.Usually high rectangular cups are formed by multi-stage deep drawing process.The thin-walled features and high rectangular shape features of aluminium alloy thin-walled high rectangular cups make the multi-stage deep drawing process of high rectangular cups more difficult.Therefore,it is very important to control the forming quality of aluminium alloy thin-walled high rectangular cups.At present,the research on the formability of 3104 aluminum alloy sheet is insufficient,the design of multi-stage deep drawing process for high rectangular cups with thin-walled features is lack of theoretical guidance,and the understanding of its forming law is not deep enough.In view of this,this paper takes the 0.25 mm thick 3104 aluminum alloy thin-walled high rectangular cups as the research object,carries out the research on the formability of 3104 aluminum alloy sheet and process of thin-walled high rectangular cups,and puts forward the corresponding solutions to the quality problems in the forming process.This paper is of great significance to improve the theory of deep drawing of thin-walled and high rectangular aluminum alloy cups and improve the forming quality.In this paper,the formability of 3104 aluminum alloy sheet is studied by physical test and simulation test.Aiming at 3104 aluminum alloy thin-walled and high rectangular cups,combined with theoretical calculation and numerical analysis,the multi-stage deep drawing process of high rectangular cups is designed and optimized,the forming quality is analyzed,and the improvement measures for the existing quality problems are put forward.The main research contents and conclusions are as follows:1)Aiming at the 3104 aluminum alloy sheet with thickness of 0.25 mm,the tensile test and forming limit test are carried out,and the deep drawing formability of 3104 aluminum alloy sheet is studied.The results show that 3104 aluminum alloy sheet has good drawing formability,and it is an ideal material for the realization of lightweight of thin-walled high rectangular cups.2)The anisotropic yield model of 3104 aluminum alloy is constructed,and the accuracy of the model is verified by the bulge test.The influence of material anisotropy on the drawing of rectangular parts is studied by numerical simulation.The results show that the larger the plane anisotropy coefficient is,the more serious the flow inhomogeneity is,the slower the material flow speed is in the corner area,and the more obvious the material thinning is.3)According to the existing theory,the multi-stage deep drawing process scheme of high rectangular cups is designed.The multi-stage deep drawing process of high rectangular cups is optimized by numerical simulation.The multi-stage deep drawing process of high rectangular cups is simulated.The forming limit and thinning rate of high rectangular cups are analyzed.The results show that the multi-stage deep drawing process scheme is reasonable.4)The multi-stage deep drawing experiment of 3104 aluminium alloy thin-walled high rectangular cups was carried out and the forming quality of the finished product was analyzed.The results show that the thickness reduction of high rectangular cups is controlled below 16%,and there is no risk of fracture,but the side wall is uneven and the structure is unstable.In order to solve this problem,the stiffeners process is used to improve it.The result shows that the shape of side wall section is effectively controlled and the structural strength is improved after adding stiffeners.