分区差异润滑对5A02铝合金三通管成形质量的影响

doi:10.3969/j.issn.1004-132X.2025.05.021

中国机械工程 ›› 2025, Vol. 36 ›› Issue (05): 1094-1102,1131.DOI: 10.3969/j.issn.1004-132X.2025.05.021

分区差异润滑对5A02铝合金三通管成形质量的影响

徐勇^1,2,3;张驰¹;解文龙^2,3* ;夏亮亮⁴;杨宝成^2,3;张士宏^2,3;黄新越⁵;王晟诚⁵

1.华北理工大学冶金与能源学院，唐山，063210
2.中国科学院金属研究所，沈阳，110016
3.沈阳市航空航天复杂构件精密制造重点实验室，沈阳，110016
4.鲁东大学交通学院，烟台,264000
5.沈阳多元机电设备有限公司，沈阳,110000

出版日期:2025-05-25 发布日期:2025-06-27
作者简介:徐勇, 男, 1983年生, 研究员。研究方向为塑性加工先进技术。 E-mail：yxu@imr.ac.cn。
基金资助:
国家自然科学基金（52405439）；中国博士后科学基金（2024M763339）；沈阳市科技计划（22-301-1-10）

Influences of Differential Lubrication on Forming Quality for 5A02 Aluminum Alloy T-shape Tubes

XU Yong^1,2,3;ZHANG Chi¹;XIE Wenlong^2,3*;XIA Liangliang⁴;YANG Baocheng^2,3;ZHANG Shihong^2,3;HUANG Xinyue⁵;WANG Shengcheng⁵

1.College of Metallurgy and Energy,North China University of Science and Technology,
Tangshan,Hebei,063210
2.Institute of Metal Research,Chinese Academy of Sciences,Shenyang，110016
3.Shenyang Key Laboratory for Aerospace Complex Components Precision Manufacturing,
Shenyang,110016
4. Transportation Department,Ludong University，Yantai,Shandong,264000
5.Shenyang Duoyuan Mechanical & Electrical Equipment Co.,Ltd.,Shenyang,110000

Online:2025-05-25 Published:2025-06-27

摘要/Abstract

摘要： 为提高三通管的成形质量，采用液压成形工艺提出了分区差异润滑方法。通过有限元模拟验证了分区差异润滑相比于传统润滑方式的优势，从材料流动性出发，对三通轴向单元和环向单元在变形过程中所受到的拉应力和压应力进行提取，分析了差异润滑区域面积大小对成形质量的影响。研究结果表明，相较于传统润滑方式，分区差异润滑能够有效地降低三通管支臂侧面和顶部的壁厚减薄率，同时可以减少侧面进给补料量从而降低失稳起皱的风险；随着胀形区润滑面积的增大，支臂单元所受的轴向拉应力逐渐减小，降低了三通支臂侧面的减薄率；随着非胀形区人工粗糙面积的增大，三通管侧壁单元所受的轴向压应力减小，但环向拉应力逐渐增大，材料更易向管身与支臂的过渡区流动，避免在管身中部出现材料堆积现象，从而降低了失稳起皱的风险。研究结果可为三通管零件的成形提供技术支撑与理论参考。

关键词: 三通管, 分区差异润滑, 液压成形, 壁厚分布

Abstract: In order to improve the forming quality of T-shape tubes, a method of differential lubrication was proposed by using hydroforming. The advantages of differential lubrication were verified by finite element simulation compared with traditional lubrication. Based on the fluidity of materials, the tensile stress and compressive stress of axial and circumferential elements of T-shape tubes were extracted during deformation. The influences of the area of the differential lubrication zones on the forming quality were analyzed. The results show that compared with the traditional lubrication method, the differential lubrication may effectively reduce the wall thickness thinning rate of the sides and tops of the T-shape tubes. Differential lubrication also may reduce the amount of side feed to reduce the risk of wrinkling. With the increasing of lubrication area in the bulging zones, the axial tensile stress of the arm element is gradually reduced, and the thinning rate of the arm sides of the T-shape tubes is reduced. With the increasing of the artificial roughing areas in the non-bulging zones, the axial compressive stress of the T-shape tubes sidewall element decreases, but the circumferential tensile stress increases gradually, and the material is more likely to flow to the transition zone of T-shape tubes, avoiding material accumulation in the middle of the tubes, thus reducing the risk of wrinkling. The research may provide technical support and theoretical reference for the forming of T-shape tubes.

Key words: T-shape tube, differential lubrication, hydroforming, thickness distribution

中图分类号:

TG386

徐勇1, 2, 3, 张驰1, 解文龙2, 3 , 夏亮亮4, 杨宝成2, 3, 张士宏2, 3, 黄新越5, 王晟诚5. 分区差异润滑对5A02铝合金三通管成形质量的影响[J]. 中国机械工程, 2025, 36(05): 1094-1102,1131.

XU Yong1, 2, 3, ZHANG Chi1, XIE Wenlong2, 3, XIA Liangliang4, YANG Baocheng2, 3, ZHANG Shihong2, 3, HUANG Xinyue5, WANG Shengcheng5. Influences of Differential Lubrication on Forming Quality for 5A02 Aluminum Alloy T-shape Tubes[J]. China Mechanical Engineering, 2025, 36(05): 1094-1102,1131.

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https://www.cmemo.org.cn/CN/Y2025/V36/I05/1094

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分区差异润滑对5A02铝合金三通管成形质量的影响

Influences of Differential Lubrication on Forming Quality for 5A02 Aluminum Alloy T-shape Tubes

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