锻压技术

大尺寸薄壁瓜瓣构件的充液成形技术研究与应用

英文标题：Research and application on hydroforming technology for large thin-walled scalloped segment component

分类号：TG394

出版年,卷(期):页码：2019,44(1):68-72

摘要：

利用充液成形技术，对运载火箭上大尺寸薄壁椭球瓜瓣构件进行工艺改进。通过仿真分析，以壁厚分布、成形质量为指标，分析液室压力等关键工艺参数的合理范围，得到液室压力加载到2 MPa即可满足瓜瓣壁厚均匀性要求，减薄分布区间在3.238%~5.703%时，可以达到理想的减薄来抑制回弹，并保证产品性能。进一步通过现场试验分析零件拉深成形后缺陷形成机制和控制措施，研究各工艺参数对零件成形质量的影响，通过控制初期液室压力并配合法兰大量润滑方式可以有效改善成形过程中的拉裂及起皱缺陷，试制出满足技术指标的椭球瓜瓣构件，成形零件型面贴胎精度小于2 mm，减薄率分布区间为3.4%~4.94%，实现了大尺寸薄壁椭球瓜瓣构件的充液成形。

The technology improvement of large thin-walled ellipsoidal scalloped segment component in carrier rocket was carried out by hydroforming technology, and taking the wall thickness distribution and forming quality as the indexes, the reasonable range of key technological parameters such as cavity pressure was analyzed by the numerical simulation. The result shows that when the cavity pressure is loaded to 2 MPa, the uniformity of wall thickness can be satisfied. When the interval of thinning rate distribution is from 3.238% to 5.703%, the ideal thinning can be realized to control springback, and the product performance can be guaranteed. Furthermore, the formation mechanism and control measures of defects after deep drawing were researched by on-site experiment analysis, and the influences of technological parameters on the forming quality of part were analyzed. The results show that the cracking and wrinkling defects during the forming process can be obviously improved by controlling the cavity pressure at the early stage of forming and lubricating the bilateral flanges largely. The ellipsoidal scalloped segment component meeting technical specifications is conducted, the shaped precision of formed part profile is less than 2 mm, the interval of thinning rate distribution is from 3.4% to 4.94%, and the hydroforming technology of large thin-walled ellipsoidal scalloped segment components is realized.

基金项目：

天津市科技计划项目（17YFZCGX00530）

田恕（1987-），女，硕士，工程师，E-mail：tian6shu@163.com

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