AZ31镁合金板材磁脉冲成形性能研究
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摘要
镁合金以其自身特有的特性如较低的密度、高比强度等逐渐受到工业应用的青睐。对于镁合金的成形方式，在以往的研究和应用中，通常采用加热成形的方法。在常温下，由于镁合金具有密排六方晶体结构，滑移系较少,成形性能较差。磁脉冲成形是一种高速成形工艺，可以显著提高金属材料的成形性能，特别是对于常温下成形性能较差的材料。本文针对工业中常用的AZ31镁合金板材进行磁脉冲成形研究。讨论和分析了AZ31镁合金板材磁脉冲成形极限、磁脉冲动态驱动下的成形性能及变形规律、AZ31镁合金板材在磁脉冲和磁脉冲动态驱动下的微观变形机制以及磁脉冲成形AZ31镁合金板材典型壳体件的变形行为。
通过分析AZ31镁合金板材磁脉冲成形下的三种典型应变状态即单向拉伸、平面应变和双等拉伸的极限应变分布，建立了AZ31镁合金板材磁脉冲室温成形极限图。利用近似矩形平板单螺旋线圈对拉伸试样（与准静态下相同）进行胀形，实现单向拉伸应变状态；利用匀压线圈产生的均匀的磁压力作用于条形试样，实现平面应变状态；利用圆形平板线圈对方形试样的自由胀形，实现双等拉应变状态。通过与准静态下相应极限应变的对比表明，AZ31镁合金板材磁脉冲成形极限显著提高。
通过成形极限的系统研究，发现AZ31镁合金板材磁脉冲成形过程中，在惯性效应的影响下成形性能显著提高。为了加强惯性效应的作用，将电导率较高的铝合金或者铜板置于AZ31镁合金板材与线圈之间，深入研究AZ31镁合金板材在磁脉冲动态驱动过程中的成形性能和变形规律。在磁脉冲动态驱动过程中，由于惯性效应的增强，AZ31镁合金板材的成形极限较无驱动时有明显提高。同时，对AZ31镁合金板材在磁脉冲动态驱动过程中典型位置的速度、应变速率和应力应变的变化规律进行了系统的研究。
通过对准静态单向拉伸、准静态双等拉伸、磁脉冲单向拉伸、磁脉冲双等拉和磁脉冲动态驱动成形（2mmAl驱动片）的断口分析，结果表明：准静态下，断口区无明显韧窝，表现为脆性断裂；而磁脉冲单向拉伸和磁脉冲动态驱动成形断口区出现明显的韧窝，表现为韧性断裂的趋势。通过对准静态单向拉伸、磁脉冲单向拉伸成形断口区域的EBSD分析，表明准静态单向拉伸下的变形机制以基系滑移为主，而磁脉冲单向拉伸下，由于变形剧烈，晶粒较准静态下细化明显，其变形机制仍以基系滑移为主，孪晶较准静态略有增多。通过对准静态双等拉伸、磁脉冲双等拉和磁脉冲动态驱动成形断口区域的EBSD分析，表明准静态双等拉伸下的变形机制为基系滑移，而磁脉冲双等拉和磁脉冲动态驱动成形下，由于变形获得了较多的能量，更多的滑移系被激活，且有{10-12}拉伸孪晶出现（其中磁脉冲动态驱动最为明显）。
采用多物理场耦合有限元分析软件ANSYS，建立了AZ31镁合金板材典型壳体件磁脉冲成形的3D有限元模型。3D有限元模型的建立，克服了磁脉冲成形以往模拟研究中只采用2D研究轴对称性结构的局限，从而可以对磁脉冲成形工艺中的非对称性结构的成形进行模拟分析。对壳体件成形中采用的匀压线圈产生的磁场分布、磁通密度和磁压力的变化规律进行了讨论和分析。研究了AZ31镁合金壳体件的磁脉冲成形过程中，板材与模具碰撞的变形特征。
针对不同底部圆角（R=30mm、R=15mm、R=2mm和R=8mm）的壳体件进行了磁脉冲成形试验研究。研究中讨论了工艺参数对壳体件成形的影响。在成形过程中，由于AZ31镁合金板材以较高的速度与模具发生碰撞，碰撞部位即壳体的底部的速度发生反向，形成凹陷。为了克服凹陷缺陷的产生，研究中探索了铝合金驱动片对于底部凹陷部位的影响规律。分析了驱动片厚度、驱动片的驱动次数对于不同底部圆角壳体件成形的影响。针对匀压线圈打火和鼓包的缺陷，提出了外导槽与主线圈进行分离的分体式匀压线圈，可以有效的减小外导槽与板材之间的接触面积，增加上下直导线之间的距离，显著提高了匀压线圈的使用寿命。
Magnesium alloy is valued to used in industry, due to it has many specialproperties such as low density, high specific strength, etc. The warm forming wasemployed to form the magnesium alloy in the previous studies and applications. Theformability of magnesium alloys at room temperature is low because they have ahexagonal close-packed crystallographic structure with limited number of slipsystems. Magnetic pulse forming is high speed forming process, which cansignificantly improve the formability of metal material especially for the materialswith poor formability at room temperature. AZ31magnesium alloy commonly usedin industry is invetigated by the magnetic pulse forming in this paper. The forminglimit of AZ31magnesium alloy of magnetic pulse forming, the formability andforming rule of magnetic pulse dynamic driving, micromechanism of AZ31magnesium alloy in magnetic pulse and magnetic pulse dynamic driving and thedeformation behaviours of typical AZ31magnesium alloy shell of magnetic pulseforming are discussed and analysed, respectively.
The forming limit diagram of AZ31magnesium alloy sheet of magnetic pulseforming is established by analyzing the three typical strain states namely uniaxialtension, plane strain and equi-biaxial tension. In order to complete uniaxial tensilestrain state, the specimens (same as that of quasi-static uniaxial tensile tests) arebulging by approximate rectangular flat single spiral coil. The uniform pressurefrom uniform coil is acted on the strip workpiece, which is used to achieve the planestrain state. Equi-biaxial tensile strain state is implemented by electromagnetic freebulging the square workpiece with circle flat spiral coil. Compared with quasi-staticforming limit accordingly, the results show that the forming limit of AZ31magnesium alloy sheet of magnetic pulse forming is remarkablely improved.
From the systematic investigation of forming limit, it shows that theformability of AZ31magnesium alloy sheet of magnetic pulse forming is enhancedbecause of inertial effect. In order to strengthen the inertial effect, the aluminumalloy or cupper sheets with higher conductivity are put between coil and AZ31sheet.The formability and forming rule of AZ31magnesium alloy sheet in magnetic pulsedynamic driving are deeply researched. Due to the strength of inetial effect, theforming limit of AZ31magnesium alloy sheet is obviously increased compared withthe case without driving. Meanwhile, the changes of velocity, strain rate and stress- strain of typical positions in magnetic pulse dynamic driving are presented.
The fracture areas of quasi-static uniaxial tension, quasi-static equi-biaxialtension, magnetic pulse uniaxial tension, magnetic pulse equi-biaxial tension andmagnetic pulse dynamic driving with2mm Al driver sheet were analyzed. Theresults show that the fractured sample for the quasi-static condition clearly displaysbrittle rupture. However, for magnetic pulse forming with the Al driver sheet, thefracture surfaces have plastic dimples that exhibit typical ductile rupture. Thedeformation mechanisms of quasi-static uniaxial tension, magnetic pulse uniaxialtension were analyzed by EBSD method. For quasi-static uniaxial tension, basalslips should be the main deformation mode. However, due to drastic deformation,grain is obviously refined in magnetic pulse uniaxial tension and twinning is morethan the case of quasi-static condition. The deformation mechanisms of quasi-staticequi-biaxial tension, magnetic pulse equi-biaxial tension and magnetic pulsedynamic driving were also analyzed by EBSD method. The results show that basalslips dominate in the quasi-static equi-biaxial tension and due to more energy fordeformation is achieved in magnetic pulse equi-biaxial tension and magnetic pulsedynamic driving, more slips and {10-12} extension twinning (it is the most obviousin magnetic pulse dynamic driving) are activated
The3D finite element model of typical AZ31magnesium alloy shell ofmagnetic pulse forming is established by using the multi-physics coupling fieldfinite element analysis software ANSYS. The establishment of3D finite elementmodel can overcome the limitation of2D model which was used to analyze the axialsymmetry structure in magnetic pulse forming.3D finite element model can beemployed to simulate the forming of non-axial symmetry structure in magneticpulse forming.The uniform coil is used to deform the shell and the change rules ofmagnetic field, magnetic flux density, magnetic pressure are analyzed anddiscussed.The deformation characteristic of sheet and die collision is investigated inAZ31magnesium alloy shell of magnetic pulse forming.
The magnetic pulse forming for AZ31magnesium alloy shell with three typicalbottom corner (R=30mm, R=15mm, R=2mm and R=8mm) is investigatedexperimentally. The effects of process parameters for forming shell are discussed.Due to AZ31magnesium alloy sheet with high velocity impacts with die, thedirection of bottom velocity is opposite. Thus, the hollow on the bottom of shell isoccurred. In order to overcome the defect of hollow, the effect of driver sheet isinvestigated. The effects of thickness of driver sheet, numbers of driving forformimg shell of different bottom corner are analyzed. Due to arcing and swell for uniform coil, the separated uniform coil viz separated the outer channel andprincipal coil is proposed. It can obviously reduce the contact area between outerchannel and sheet, increase the distance between up and down lead and remarkablyimprove the life of uniform coil.
通过分析AZ31镁合金板材磁脉冲成形下的三种典型应变状态即单向拉伸、平面应变和双等拉伸的极限应变分布，建立了AZ31镁合金板材磁脉冲室温成形极限图。利用近似矩形平板单螺旋线圈对拉伸试样（与准静态下相同）进行胀形，实现单向拉伸应变状态；利用匀压线圈产生的均匀的磁压力作用于条形试样，实现平面应变状态；利用圆形平板线圈对方形试样的自由胀形，实现双等拉应变状态。通过与准静态下相应极限应变的对比表明，AZ31镁合金板材磁脉冲成形极限显著提高。
通过成形极限的系统研究，发现AZ31镁合金板材磁脉冲成形过程中，在惯性效应的影响下成形性能显著提高。为了加强惯性效应的作用，将电导率较高的铝合金或者铜板置于AZ31镁合金板材与线圈之间，深入研究AZ31镁合金板材在磁脉冲动态驱动过程中的成形性能和变形规律。在磁脉冲动态驱动过程中，由于惯性效应的增强，AZ31镁合金板材的成形极限较无驱动时有明显提高。同时，对AZ31镁合金板材在磁脉冲动态驱动过程中典型位置的速度、应变速率和应力应变的变化规律进行了系统的研究。
通过对准静态单向拉伸、准静态双等拉伸、磁脉冲单向拉伸、磁脉冲双等拉和磁脉冲动态驱动成形（2mmAl驱动片）的断口分析，结果表明：准静态下，断口区无明显韧窝，表现为脆性断裂；而磁脉冲单向拉伸和磁脉冲动态驱动成形断口区出现明显的韧窝，表现为韧性断裂的趋势。通过对准静态单向拉伸、磁脉冲单向拉伸成形断口区域的EBSD分析，表明准静态单向拉伸下的变形机制以基系滑移为主，而磁脉冲单向拉伸下，由于变形剧烈，晶粒较准静态下细化明显，其变形机制仍以基系滑移为主，孪晶较准静态略有增多。通过对准静态双等拉伸、磁脉冲双等拉和磁脉冲动态驱动成形断口区域的EBSD分析，表明准静态双等拉伸下的变形机制为基系滑移，而磁脉冲双等拉和磁脉冲动态驱动成形下，由于变形获得了较多的能量，更多的滑移系被激活，且有{10-12}拉伸孪晶出现（其中磁脉冲动态驱动最为明显）。
采用多物理场耦合有限元分析软件ANSYS，建立了AZ31镁合金板材典型壳体件磁脉冲成形的3D有限元模型。3D有限元模型的建立，克服了磁脉冲成形以往模拟研究中只采用2D研究轴对称性结构的局限，从而可以对磁脉冲成形工艺中的非对称性结构的成形进行模拟分析。对壳体件成形中采用的匀压线圈产生的磁场分布、磁通密度和磁压力的变化规律进行了讨论和分析。研究了AZ31镁合金壳体件的磁脉冲成形过程中，板材与模具碰撞的变形特征。
针对不同底部圆角（R=30mm、R=15mm、R=2mm和R=8mm）的壳体件进行了磁脉冲成形试验研究。研究中讨论了工艺参数对壳体件成形的影响。在成形过程中，由于AZ31镁合金板材以较高的速度与模具发生碰撞，碰撞部位即壳体的底部的速度发生反向，形成凹陷。为了克服凹陷缺陷的产生，研究中探索了铝合金驱动片对于底部凹陷部位的影响规律。分析了驱动片厚度、驱动片的驱动次数对于不同底部圆角壳体件成形的影响。针对匀压线圈打火和鼓包的缺陷，提出了外导槽与主线圈进行分离的分体式匀压线圈，可以有效的减小外导槽与板材之间的接触面积，增加上下直导线之间的距离，显著提高了匀压线圈的使用寿命。
Magnesium alloy is valued to used in industry, due to it has many specialproperties such as low density, high specific strength, etc. The warm forming wasemployed to form the magnesium alloy in the previous studies and applications. Theformability of magnesium alloys at room temperature is low because they have ahexagonal close-packed crystallographic structure with limited number of slipsystems. Magnetic pulse forming is high speed forming process, which cansignificantly improve the formability of metal material especially for the materialswith poor formability at room temperature. AZ31magnesium alloy commonly usedin industry is invetigated by the magnetic pulse forming in this paper. The forminglimit of AZ31magnesium alloy of magnetic pulse forming, the formability andforming rule of magnetic pulse dynamic driving, micromechanism of AZ31magnesium alloy in magnetic pulse and magnetic pulse dynamic driving and thedeformation behaviours of typical AZ31magnesium alloy shell of magnetic pulseforming are discussed and analysed, respectively.
The forming limit diagram of AZ31magnesium alloy sheet of magnetic pulseforming is established by analyzing the three typical strain states namely uniaxialtension, plane strain and equi-biaxial tension. In order to complete uniaxial tensilestrain state, the specimens (same as that of quasi-static uniaxial tensile tests) arebulging by approximate rectangular flat single spiral coil. The uniform pressurefrom uniform coil is acted on the strip workpiece, which is used to achieve the planestrain state. Equi-biaxial tensile strain state is implemented by electromagnetic freebulging the square workpiece with circle flat spiral coil. Compared with quasi-staticforming limit accordingly, the results show that the forming limit of AZ31magnesium alloy sheet of magnetic pulse forming is remarkablely improved.
From the systematic investigation of forming limit, it shows that theformability of AZ31magnesium alloy sheet of magnetic pulse forming is enhancedbecause of inertial effect. In order to strengthen the inertial effect, the aluminumalloy or cupper sheets with higher conductivity are put between coil and AZ31sheet.The formability and forming rule of AZ31magnesium alloy sheet in magnetic pulsedynamic driving are deeply researched. Due to the strength of inetial effect, theforming limit of AZ31magnesium alloy sheet is obviously increased compared withthe case without driving. Meanwhile, the changes of velocity, strain rate and stress- strain of typical positions in magnetic pulse dynamic driving are presented.
The fracture areas of quasi-static uniaxial tension, quasi-static equi-biaxialtension, magnetic pulse uniaxial tension, magnetic pulse equi-biaxial tension andmagnetic pulse dynamic driving with2mm Al driver sheet were analyzed. Theresults show that the fractured sample for the quasi-static condition clearly displaysbrittle rupture. However, for magnetic pulse forming with the Al driver sheet, thefracture surfaces have plastic dimples that exhibit typical ductile rupture. Thedeformation mechanisms of quasi-static uniaxial tension, magnetic pulse uniaxialtension were analyzed by EBSD method. For quasi-static uniaxial tension, basalslips should be the main deformation mode. However, due to drastic deformation,grain is obviously refined in magnetic pulse uniaxial tension and twinning is morethan the case of quasi-static condition. The deformation mechanisms of quasi-staticequi-biaxial tension, magnetic pulse equi-biaxial tension and magnetic pulsedynamic driving were also analyzed by EBSD method. The results show that basalslips dominate in the quasi-static equi-biaxial tension and due to more energy fordeformation is achieved in magnetic pulse equi-biaxial tension and magnetic pulsedynamic driving, more slips and {10-12} extension twinning (it is the most obviousin magnetic pulse dynamic driving) are activated
The3D finite element model of typical AZ31magnesium alloy shell ofmagnetic pulse forming is established by using the multi-physics coupling fieldfinite element analysis software ANSYS. The establishment of3D finite elementmodel can overcome the limitation of2D model which was used to analyze the axialsymmetry structure in magnetic pulse forming.3D finite element model can beemployed to simulate the forming of non-axial symmetry structure in magneticpulse forming.The uniform coil is used to deform the shell and the change rules ofmagnetic field, magnetic flux density, magnetic pressure are analyzed anddiscussed.The deformation characteristic of sheet and die collision is investigated inAZ31magnesium alloy shell of magnetic pulse forming.
The magnetic pulse forming for AZ31magnesium alloy shell with three typicalbottom corner (R=30mm, R=15mm, R=2mm and R=8mm) is investigatedexperimentally. The effects of process parameters for forming shell are discussed.Due to AZ31magnesium alloy sheet with high velocity impacts with die, thedirection of bottom velocity is opposite. Thus, the hollow on the bottom of shell isoccurred. In order to overcome the defect of hollow, the effect of driver sheet isinvestigated. The effects of thickness of driver sheet, numbers of driving forformimg shell of different bottom corner are analyzed. Due to arcing and swell for uniform coil, the separated uniform coil viz separated the outer channel andprincipal coil is proposed. It can obviously reduce the contact area between outerchannel and sheet, increase the distance between up and down lead and remarkablyimprove the life of uniform coil.
引文
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