异径铝合金薄壁圆管的加热塑性连接方法与模具设计

Tool Design of Heating Plastic Connection for Unequal Diameter Aluminum Thin-Walled Tubes

摘要:

铝合金薄壁管在轴向压缩连接时开裂导致连接失效。为提高铝合金的压缩塑性成形性，进行了可加热的不等径管塑性连接模具设计。利用有限元软件对加热塑性连接过程中模具的热应力和热传递进行了数值模拟，用正交试验法对模具散热系统结构参数进行了分析，并进行了模具制作和不等直径铝合金管的连接接头试制。结果表明，20 ℃和600 ℃下模具的最大应力均低于模具材料对应温度下的屈服强度，满足钢、铝金属材料的加热塑性连接工艺需求。设计的散热系统可有效减缓模具热量向拉伸机的传递。300 ℃下该模具成功将Φ44和Φ30的两铝合金管进行了连接。说明了模具设计的合理性和连接工艺的可行性。为后续的工程应用提供指导。

Abstract:

Aluminum thin-walled tube can be cracked during axial compression connection， which can result in connection failure. To improve the compressional plastic formability of aluminum alloy， a heating plastic connection tool for unequal diameter thin-walled tubes was designed in the paper. The thermal stress and heat transfer of the tool in the process of heating plastic connection were numerically simulated by finite element software. The cooling system structural parameters were analyzed by using the orthogonal test method. The tool and the trial unequal diameter aluminum joint were manufactured. The results show that the maximum stress of the tool at 20 ℃ and 600 ℃ are lower than the yielding strength of the material at the corresponding temperature， which meets the requirements of heating plastic connection process for steel and aluminum. The cooling system designed can effectively slow down the heat transfer from the tool to the tensile machine. The joint of φ44 and φ30 is successfully connected by the tool at 300 ℃， which verifies the rationality of the tool design and the feasibility of the connection process， provideing guidance for subsequent engineering application.