薄壁曲面整体构件流体压力成形起皱机理与控制

doi:10.3901/JME.2018.09.037

机械工程学报 ›› 2018, Vol. 54 ›› Issue (9): 37-44.doi: 10.3901/JME.2018.09.037

• 特邀专栏：航天先进制造技术专栏 • 上一篇下一篇

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薄壁曲面整体构件流体压力成形起皱机理与控制

刘伟^1,2, 徐永超^1,2, 陈一哲¹, 苑世剑^1,2, 胡蓝³, 张志超³, 郭立杰³

1. 哈尔滨工业大学材料科学与工程学院哈尔滨 150001;
2. 哈尔滨工业大学金属精密热加工国防科技重点实验室哈尔滨 150001;
3. 上海航天设备制造总厂上海 200245

收稿日期:2017-06-30 修回日期:2017-11-15 出版日期:2018-05-05 发布日期:2018-05-05
通讯作者: 刘伟(通信作者),男,1977年出生,博士,副教授,博士研究生导师。主要研究方向为板材流体压力成形。E-mail:liuw@hit.eud.cn
作者简介:苑世剑,男,1963年出生,博士,教授,博士研究生导师,长江学者特聘教授,国家杰出青年基金获得者。主要研究方向为流体压力成形技术与装备。E-mail:syuan@hit.edu.cn
基金资助:
国家自然科学基金（U1637209）和国家重点研发计划（2017YFB0306300）资助项目。

Mechanism and Controlling of Wrinkles during Hydroforming of Integral Thin-walled Curved Shell

LIU Wei^1,2, XU Yongchao^1,2, CHEN Yizhe¹, YUAN Shijian^1,2, HU Lan³, ZHANG Zhichao³, GUO Lijie³

1. School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001;
2. National Key Laboratory for Precision Hot Processing of Metals, Harbin Institute of Technology, Harbin 150001;
3. Shanghai Aerospace Equipments Manufacture, Shanghai 200245

Received:2017-06-30 Revised:2017-11-15 Online:2018-05-05 Published:2018-05-05

摘要/Abstract

摘要： 塑性失稳诱发起皱是制约薄壁曲面构件整体成形的瓶颈问题，通过考虑悬空区反胀效果的曲面薄壳流体压力成形力学分析，推导抑制起皱和破裂的非线性流体压力加载曲线，建立临界起皱应力模型为塑性失稳提供理论判据；在此基础上，针对大型贮箱整体箱底构件流体压力成形起皱预测和控制难题，理论计算大型箱底流体压力成形加载路径，分析流体压力加载路径对反胀区形状、失稳行为和应力分布影响规律，揭示曲面薄壳流体压力成形起皱抑制机理；采用我国自主研制的超大型数控流体压力成形装备（成形力1.5万t/高压液体体积5 m³），首次试制出直径3 m级运载火箭燃料贮箱整体箱底，解决了大型超薄（厚径比2‰）曲面薄壳失稳难题。

关键词: 薄壁曲面构件, 流体压力成形, 起皱, 塑性失稳

Abstract: Wrinkling induced by plastic instability is a critical problem for the forming of integral thin-walled curved shells. Considering the reverse bulging effect in unsupported area, the mechanical characteristics of sheet hydroforming process is analyzed. Loading paths of liquid pressure about wrinkling and rupture are deduced, a model about critical wrinkling stress is built which can be regarded as a criterion for the plastic instability. Focusing on the forming process of storage tanks of rockets, a theoretical loading path is calculated, the influence of loading path on bulging geometry, instability behavior and stress distribution is discussed. The mechanism of wrinkling suppression is revealed. A large numerical control sheet hydroforming equipment with the biggest power in the world was successfully built (forming power 15000 t, volume of high pressure liquid 5 m³). An integral storage tank with diameter of 3m is successfully obtained using the proposed method and equipment. The problem on plastic instability of thin-walled shell (ratio of thickness to diameter equals 2‰) is solved.

Key words: plastic instability, sheet hydroforming, thin-walled curved shell, wrinkling

中图分类号:

TG394

刘伟, 徐永超, 陈一哲, 苑世剑, 胡蓝, 张志超, 郭立杰. 薄壁曲面整体构件流体压力成形起皱机理与控制[J]. 机械工程学报, 2018, 54(9): 37-44.

LIU Wei, XU Yongchao, CHEN Yizhe, YUAN Shijian, HU Lan, ZHANG Zhichao, GUO Lijie. Mechanism and Controlling of Wrinkles during Hydroforming of Integral Thin-walled Curved Shell[J]. Journal of Mechanical Engineering, 2018, 54(9): 37-44.

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薄壁曲面整体构件流体压力成形起皱机理与控制

Mechanism and Controlling of Wrinkles during Hydroforming of Integral Thin-walled Curved Shell

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