鋁管液壓沖邊成形之有限元素分析

Finite Element Analysis of Hydro-Flanging of Aluminum Tubes

黃永茂(Yeong-Maw Hwang) ； 范鴻仁(Hong Nhan Pham) ； 徐曉珊(Hiu Shan Rachel Tsui)

《鍛造》 30卷1期 (2021/04) Pp. 18-26

摘要

管件與外部的連接可透過液壓沖孔、擴孔和螺帽鑲埋來達到，而液壓沖邊是整個液壓結合成形的預成形。本研究使用有限元素軟體DEFORM 3D來分析鋁合金6063管的圓孔擴孔過程之可成形性，並把分析結果與實驗結果作比較，以驗證解析模式的妥當性。本研究分別採用了30﹑50和70 MPa三種內部壓力進行鼓脹支撐以取代傳統剛性模具，並設計了三種不同的沖頭形狀進行液壓沖孔及擴孔，以防止內部液體在沖頭和穿孔管材之間洩漏。另外亦探討了不同沖頭形狀、內部壓力及沖孔直徑對擴孔效應及成品厚度分佈之影響。

並列摘要

The connection between a tube and the external can be achieved through hydro-piercing, hole flanging and nut laying, where hydro-flanging is the preform of the whole hydro-joining process. In this study, the formability of the round hole reaming process of aluminum alloy 6063 tube was analyzed using the finite element software DEFORM 3D and the results were compared with those obtained by experiments in order to ensure the appropriateness of the analysis. Drum expansion support was carried out with three internal pressures of 30, 50 and 70 MPa respectively to replace the traditional rigid die and three different punch shapes were designed for hydro-piercing and reaming so as to prevent the internal liquid from leaking between the punch and the tube. In addition, the influence of punch shapes, internal pressures and piercing diameters on reaming effect and thickness distribution of the final product were investigated.