(1. 湘潭大学 机械工程学院，湘潭 411105； 2. 华中科技大学 材料成形与模具技术国家重点实验室，武汉 430074； 3. 日本岐阜大学 机械系统工学科，岐阜 501-1193)
摘 要: 以铝合金筒形件底部实心凸起成形为例，提出采用拉深-镦挤板锻造工艺成形中心实心凸起结构，结合有限元模拟技术及工艺实验方法，比较传统反挤压工艺与板锻造工艺成形实心凸起结构的异同。结果表明：当成形同一凸起高度时，板锻造成形载荷比反挤压成形载荷减小一倍左右。板锻造成形过程中，底部分流面位置先内移后趋于稳定；而在反挤压成形过程中，底部分流面位置先趋于稳定后外移。凸模与板料上表面的单面润滑可有效防止底部缩孔缺陷。
关键字: 铝合金板材；实心凸起；板锻造；分流面；缩孔机制
（1. School of Mechanical Engineering, Xiangtan University, Xiangtan 411105, China; 2. State Key Laboratory of Materials Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China; 3. Department of Mechanical and Systems Engineering, Gifu University, Gifu501-1193, Japan）
Abstract:A new solid boss plate forging process named compression-drawing method was proposed to form the aluminum alloy sheet. The finite element method with DEFORM-2D and experiments were used to investigate the solid boss forming process. As a result, the forming load of back-extrusion is about two times higher than that of plate forging when the same height boss is acquired. During the solid boss forming, the location of separation flow surface first moves inner side and then remains stable as for plate forging, while it first remains stable and then moves outer side as for back extrusion. Besides, single lubrication between punch and upper side of workpiece can prevent the dimple defect.
Key words: aluminum alloy sheet; solid boss; plate forging; separation flow surface; dimple defect mechanism
