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摘要：
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提出大尺度薄壁曲面整体构件流体压力成形新技术，建立了曲面薄壳流体压力成形理论模型，分析了材料参数、几何参数对流体压力的影响规律，采用能量法解析出临界起皱应力，获得了厚径比、流体压力对临界起皱应力的影响规律；通过工艺实验建立了流体压力成形工艺窗口，验证了临界流体压力预测的正确性。开展了3 m级薄壁曲面构件流体压力成形工艺仿真，分析了加载路径对反胀区形状、应力的影响，获得了合理的流体压力；研发出世界上最大的数控流体压力成形装备，最大成形力为150 MN，流体体积为5 m3。开展了大型铝合金薄壁曲面构件(厚径比<2‰)的成形工艺研制，在国际上首次采用厚度与构件相同的铝合金薄板直接成形3 m级整体薄壁曲面构件。
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The innovative technology of hydroforming for integrated thin-walled curved parts with large size was proposed, and the theoretical model of hydroforming was built for thin-walled curved parts. Then, the influence laws of material and geometrical parameters on the fluid pressure were analyzed, and the influence laws of the ratio of thickness to diameter and the fluid pressure on the critical wrinkle stress were obtained by using energy method to analyze the critical winkle stress. Furthermore, the process window of hydroforming was built by experiments to verify the correctness of critical fluid pressure prediction, and the influences of loading paths on the shape and stress of reverse bulging region were analyzed by simulating the hydroforming process of thin-walled curved part with 3 m in diameter to obtain the optimal fluid pressure. Finally, the CNC hydroforming machine was developed with the maximum drawing force of 150 MN and the liquid volume of 5 m3, which was the biggest one in the world. Thus, the research on hydroforming process was conducted for large thin-walled curved part of aluminum alloy with the ratio of thickness to diameter lower than 2‰, and an integral thin-walled curved part with 3 m in diameter was directly formed for the first time in the world by the aluminum alloy plate with the thickness as same as the final component.
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基金项目：
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国家重点研发计划（2017YFB0306304）；国家自然科学基金重点项目（U1637209）
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作者简介：
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刘伟（1977-），男，博士，教授，E-mail：liuw@hit.edu.cn
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参考文献：
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