锻压技术

复杂三维扭曲空心叶片充液压制工艺

英文标题：Hydro-pressing process for complex three-dimensional twisted hollow blade

分类号：TG386

出版年,卷(期):页码：2023,48(8):90-95

摘要：

针对一种航空发动机复杂三维扭曲空心叶片进行充液压制工艺研究。通过有限元分析软件对空心叶片充液压制过程进行数值模拟，探究管坯长度、密封推头结构和充液压力对GH4169高温合金薄壁管充液压制成形过程中的管坯贴模情况、壁厚及尺寸的影响，并进行试验验证。结果表明：管坯长度越短，管坯两端的材料越容易向中间流动，管坯易起皱。采用锥形密封推头有效改善了材料流动，可实现管坯简单、有效的密封。采用充液压制工艺可使管坯在较低的充液压力下成形出小半径圆角。当管坯长度为240 mm、充液压力为9 MPa时，管坯的贴模性较好，最小圆角半径为1.0 mm，最大壁厚减薄率为4.1%。试验结果和数值模拟结果一致，成形出的空心叶片表面质量良好，壁厚均匀、减薄小，满足尺寸精度要求，达到了复杂三维扭曲空心叶片短流程、低成本、高精密成形的目的。

The research on hydro-pressing process for complex three-dimensional twisted hollow blade of an aero-engine was carried out, and the hydro-pressing process for hollow blade was numerically simulated by finite element analysis software. Then, the influences of length of tube blank, structure of sealing push head and hydro-forming pressure on die fittingness of tube blank, wall thickness and size during the hydro-pressing process of superalloy GH4169 thin-walled tube were investigated, and the test verification was carried out. The results show that the shorter the length of tube blank is, the easier the material at both ends of tube blank flows to the middle, and the tube blank is easy to wrinkle. The tapered sealing push head is used to effectively improve the material flow and realize the simple and effective sealing of tube blank. A small radius fillet of tube blank is formed under a relatively low hydro-forming pressure by the hydro-pressing process. When the length of tube blank is 240 mm and the hydro-forming pressure is 9 MPa, the die fittingness of tube blank is good, the minimum fillet radius is 1.0 mm and the maximum wall thickness thinning rate is 4.1%. The test results are consistent with the numerical simulation results. The formed hollow blades with good surface quality, uniform wall thickness and small thinning meet the requirements of dimensional accuracy. The purpose of short-process, low-cost and high-precision forming of complex three-dimensional twisted hollow blades is realized.

基金项目：

作者简介：胡加敏（1992-），男，博士，工程师,E-mail：jiamin.hu@foxmail.com

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