Transactions of Materials and Heat Treatment

Title：Numerical simulation and application on multi-layer bellows forming based on finite element

Authors： Jian Hanming Song Ke Yuan Xing Yang Bin Zhang Liufeng Feng Sule Zhu Yeqing

Unit： Shanghai Spaceflight Precision Machinery Institute

KeyWords： multi-layer bellows hydroforming forming pressure wall thickness reduction multi-layer structure

ClassificationCode：TG394

year,vol(issue):pagenumber：2023,48(5):260-265

Abstract：

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.

Funds：

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

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