【摘要】 目的 为保证运载装备高功效轻量化的同时，提升其支撑防护结构的成形性能，提出一种铝合金薄壁高筋构件电冲击复合锻挤成形工艺方法，并探究模具下压量、电流密度对铝合金薄壁高筋构件成形质量的影响。方法 通过DEFORM-3D仿真软件模拟分析2024-T4铝合金薄壁高筋构件电冲击复合锻挤下材料流动和填充规律，并对仿真分析结果进行电冲击复合锻挤成形试验验证。结果 仿真模拟表明：随着模具下行，材料流动和填充难度增加，成形质量下降，不同电流密度对薄壁高筋构件成形影响程度不同。通过不同的电流密度进行试验，得到薄壁高筋构件最佳成形工艺。试验结果表明：当坯料预热至300℃，脉冲电流值为600 A时，成形后构件未见明显的开裂和填充不满等缺陷，成形的筋高提升35.14%，成形质量最好。结论 与无电冲击的薄壁高筋构件相比，电冲击复合锻挤成形时构件整体成形性能提升，这是由于构件受脉冲电流焦耳热效应和非热效应的影响，金属流动性增强，成形载荷降低，更容易填充模具型腔。更多还原

【Abstract】 The work aims to a propose a composite forging and extrusion process method for aluminum alloy thin-walled and high-rib components and explore the effect of mold pressing and current density on the forming quality of aluminum alloy thin-walled and high-rib components, so as to ensure the high efficiency and lightweight of transportation equipment, and to improve the formability of its supporting and protective structures. By using DEFORM-3D simulation software, the material flow and filling rules of 2024-T4 aluminum alloy thin-walled and high-rib components under electroshock composite forging and extrusion were simulated and analyzed. Then, based on the simulation analysis results, electroshock composite forging and extrusion forming experiments were conducted to verify the results. Simulation results showed that as the mold descended, the difficulty of material flow and filling increased, and the forming quality decreased. Different current densities had varying degrees of effect on the forming of thin-walled and high-rib components. By conducting experiments with different current densities, the optimal forming process for thin-walled and high-rib components was obtained. The experimental results showed that when the blank was preheated to 300 ℃ a nd the pulse current value was 600 A, there were no obvious cracks or insufficient filling defects in the formed components. The formed rib height increased by 35.14%, and the forming quality was the best. Compared with thin-walled and high-rib components without electroshock, the overall formability of the components is improved during electroshock composite forging and extrusion forming. This is because the components are affected by the Joule thermal effect and non-thermal effect of pulse current, which enhances the metal fluidity, reduces the forming load, and makes it easier to fill the mold cavity.更多还原