超声振动辅助金属箔板微冲裁成形机理与断面质量控制

金属箔板微型构件是惯性导航等系统的核心构件之一，目前采用冲裁成形后再切削加工的方法，制造效率和成形件合格率均很低，严重制约了导航精度等系统性能的提高。为此，本项目提出超声振动辅助箔板微冲裁成形新工艺，利用超声振动塑性成形的Blaha效应和表面效应，抑制微冲裁剪切变形中的裂纹萌生与扩展，提升箔板塑性变形均匀性，降低接触摩擦力，以提高微冲裁成形质量。开展超声振动金属箔板塑性变形性能和断裂行为研究，基于晶体塑性理论和应力叠加原理，构建超声振动下箔板材料本构模型；研究多约束作用下箔板微冲裁剪切变形规律，揭示箔板微冲裁剪切变形尺寸效应、裂纹萌生与扩展机理，探讨超声振动下接触摩擦行为，探索箔板微型构件断面质量控制方法；开展超声振动辅助微冲裁成形工艺研究，揭示超声振动辅助金属箔板微冲裁成形机理，实现高质量箔板微型构件的精密一次成形，促进其在实际生产中的广泛应用，具有重要的实用价值和科学意义。

Micro foil part is one of key components used in inertial navigation system. This kind of parts are fabricated with the blanking and machining process. The manufacture efficiency and qualified rate of parts are both very low, which restricts the improvement of inertial accuracy. Then, the ultrasonic vibration assisted micro foil blanking process is carried out as a kind of new process in the project. For the Blaha effects and surface effects in the ultrasonic vibration plastic deformation, the crack initiation and propagation is restricted, and the properties of plastic deformation could be improved, and the friction at contact surface becomes lower. Then, the quality of micro blanking is raised. We will study the plastic deformation and fracture behaviors of metal foils under ultrasonic vibration. Based on the crystal plasticity theory and principle of superimposed stresses, the constitutive model of metal foil will be established under ultrasonic vibration. The shear deformation in micro foil blanking will be investigated on the condition of multiple constraints. The size effects of shear deformation in micro blanking and mechanism of crack initiation and propagation will be analyzed. And the tribological behaviors under ultrasonic vibration will be studied. The process for control of cross section quality will be explored. The investigation of ultrasonic vibration assisted micro blanking process will be carried out to reveal its mechanism. Finally, the micro foil parts with high quality will be accurately formed at only one time. It will promote the wide application of microparts in practical production, which has important practical value and scientific significance.