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摘要：
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传统管材充液成形工艺在成形大胀形率复杂截面零件过程中，受模具形面限制，材料很难在环向均匀流动，从而导致成形失败。针对以上问题，利用有限元仿真方法，总结危险点的成形规律，建立几何模型与力学模型，得到应力沿环向的分布规律，指出危险点变形失稳的原因。在此基础之上，将材料沿环向的变形过程分解为在环上的拉伸变形和在形状上的屈曲变形两个阶段，提出了一种新的多步管材充液成形工艺，并以某型航空发动机的导流叶片衬管为例，进行试验验证。结果表明，多步管材充液成形工艺可以有效降低材料在高压成形阶段的减薄，提高成形精度，降低设备负载。
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In the process of large expansion rate parts with complex cross section formed by the traditional hydroforming process, it is difficult for the materials to flow uniformly in the ring direction due to the die surface restriction, and the failure of forming occurs. For the above problems, the forming law of the dangerous points was summarized, the geometrical model and the mechanical model were established, the distribution law of the stress along the circumferential direction was obtained, and the reason of the deformation instability of the dangerous point was pointed out by the finite element simulation method. Then, a new process of multi-step hydroforming process was presented by decomposing the material along the circumferential deformation process into two stages namely, tensile deformation on the ring and buckling deformation on the shape, and the tests were verified for the guide vane liner tube of the aero-engine. Results show that the multi-step tube hydroforming technology can effectively reduce the thinning of materials at high pressure forming stage to improve the forming precision and reduce equipment load.
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基金项目：
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作者简介：
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作者简介：阮尚文（1987-），男，博士研究生
E-mail：ruanshangwen@buaa.edu.cn
通讯作者：郎利辉（1970-），男，博士，教授
E-mail：lang@buaa.edu.cn
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