新一代动车组铝合金受电弓导流板超塑成形技术研究

The superplastic positive-reverse bulging process was applied to form the pantograph deflector plate of the new-generation EMUs. The formed sheet was domestically supplied 5083-H111 aluminum alloy in as-received condition. Based on the simulation analysis of the positive-reverse bulging processes using finite element simulation software, the bulging degree of the reverse bulging was determined. By analyzing the results of positive bulging with different strain rates, the optimal strain rate of superplastic forming was determined, and the air pressure loading curve of the superplastic positive-reverse bulging process was established according to the simulation results. During the mold designing stage, stiffeners were incorporated into the positive bulging mold to prevent deformation of parts based on the geometric characteristics of the pantograph deflector plate. The results show that pantograph deflector plates of EMUs are formed by positive-reverse bulging process. The accuracy of the formed parts is comply with technical standards, showing no detectable defects. The wall thickness distribution exhibits uniformity across the component, with the thinning rate satisfying the specified requirements (≤10% for global thinning rate and ≤30% for localized thinning rate). The maximum thinning rate is 29. 75%.