锻压技术

基于有限元的多层波纹管成形数值模拟及应用

英文标题：Numerical simulation and application on multi-layer bellows forming based on finite element

分类号：TG394

出版年,卷(期):页码：2023,48(5):260-265

摘要：

对运载火箭增压输送系统管路用外径为Φ60 mm、壁厚为0.35 mm的双层波纹管的整体液压成形过程进行有限元数值仿真，通过在有限元分析软件中设置不同的边界条件，模拟多层波纹管的成形压力和壁厚减薄量等关键工艺参数及成形结果。通过对目标多层波纹管整体液压成形进行工艺试验，对有限元分析结果进行验证。结果表明：波纹管液压成形压力应使管坯材料应力大于屈服强度，方可顺利成形出波纹管产品，即成形压力应大于10 MPa；具体成形压力的选择应根据波形饱满程度、最大等效应力值及壁厚减薄量综合考虑，故选择15 MPa作为成形压力；波纹管壁厚在波峰处的减薄量最大，并由波峰至波谷递减，最小壁厚为0.57 mm。

The finite element numerical simulation of the integral hydroforming process for double-layer bellows with the outer diameter of Φ60 mm and the wall thickness of 0.35 mm for the pipeline of launch vehicle booster delivery system was carried out. Then, by setting different boundary conditions in the finite element analysis software, the key process parameters such as forming pressure and wall thickness reduction of the multi-layer bellows and the forming results were simulated. Furthermore, the finite element analysis results were verified by the process experiment of the integral hydroforming for target multi-layer bellows. The results show that the hydroforming pressure of bellows should make the stress of tube blanks greater than the yield strength to form the bellow products smoothly, namely, the forming pressure should be greater than 10 MPa. The appropriate forming pressure should be selected according to the fullness of waveform, the maximum equivalent stress value and the wall thickness reduction. Thus, 15 MPa is selected as the forming pressure. The wall thickness reduction is greatest at the peak, and the reduction decreases from the peak to the trough，and the minimum wall thickness is 0.57 mm.

基金项目：

作者简介：简翰鸣(1992-)，男，硕士，工程师,E-mail：jianhanming@sina.com

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