发动机变壁厚变直径管件缩胀成形力学模型与变形规律

doi:10.3901/JME.2025.14.352

机械工程学报 ›› 2025, Vol. 61 ›› Issue (14): 352-361.doi: 10.3901/JME.2025.14.352

• 交叉与前沿 • 上一篇

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发动机变壁厚变直径管件缩胀成形力学模型与变形规律

陈一哲^1,2, 孙润远^1,2, 赵世龙^1,2, 孙瑛钦², 华林^1,2

1. 武汉理工大学高温轻合金及应用技术全国重点实验室武汉 430070;
2. 武汉理工大学汽车工程学院武汉 430070

收稿日期:2024-11-05 修回日期:2025-01-07 发布日期:2025-08-25
作者简介:陈一哲，男，1990年出生，博士，教授。主要研究方向为轻量化技术。E-mail:yzchen@whut.edu.cn;华林(通信作者)，男，1962年出生，博士，教授。主要研究方向为塑性理论与技术。E-mail:hualin@whut.edu.cn
基金资助:
国家自然科学基金资助项目(52373320，52422510，52175360，52472383)。

Study on Mechanical Model and Deformation Characteristics of Tube Upseting-bulging Method on Engine Tubes with Variable Wall Thickness and Diameter

CHEN Yizhe^1,2, SUN Runyuan^1,2, ZHAO Shilong^1,2, SUN Yingqin², HUA Lin^1,2

1. Stated Key Laboratory of Super Alloys and Application Technology, Wuhan University of Technology, Wuhan 430070;
2. School of Automotive Engineering, Wuhan University of Technology, Wuhan 430070

Received:2024-11-05 Revised:2025-01-07 Published:2025-08-25

摘要/Abstract

摘要： 喷管是一种典型发动机变壁厚变直径管件，传统的喷管制造过程中存在成形极限低、易失稳起皱等难题。为此，提出缩胀成形新思路，方法内涵是在内部软模作用和外部刚模限制下，管材小端缩口增厚、大端胀形减薄，实现缩胀一体化成形。在此基础上，建立管材缩胀成形力学模型，开展缩胀成形过程数值模拟，获得变形过程应力、应变与壁厚变化规律，明确缩胀成形缺陷演变与控制方法，建立试验工装并进行了验证。结果表明：采用缩胀成形管材小端直径减小、壁厚增厚，管材大端直径增大、壁厚减薄；制造出壁厚变化率达±20%、直径变化率达50%的缩胀成形管件，验证了理论推导和有限元仿真的正确性。研究表明缩胀成形是一种极具潜力的变壁厚变直径管件精准制造方法。

关键词: 塑性成形, 缩口起皱, 发动机喷管, 管材壁厚分布

Abstract: Nozzle is a typical tube with variable wall thickness and diameters of the engine. Facing the challenges of low forming limits and susceptibility of wrinkles in traditional forming methods, the study proposed a tube upsetting-bulging forming process. The core technical approach is to achieve necking and thickening at the small end, while achieve bulging and thinning at the large end, with the action of an internal flexible mold and the restriction of an external rigid mold. A theoretical model for tube upseting-bulging method is established and simulations analysis of tube upseting-bulging method are conducted. The stress, strain, and thickness distribution are obtained. The defect evolutions and control methods are clarified, and experimental tooling is developed and validated. The results show that, the diameter of the small end is reduced and the wall thickness is increased, while the diameter of the large end is increased and the wall thickness is reduced. The tube with a wall thickness variation rate of ±20% and a diameter variation rate of 50% is successfully manufactured, which confirms the validity of the theoretical model and finite element simulation. The study reveals that tube upsetting-bulging method is an exceptionally technique for the precise manufacturing of tubes with variable thicknesses and diameters.

Key words: plastic forming, wrinkling, rocket nozzle, thickness distribution of tube

中图分类号:

TG38

陈一哲, 孙润远, 赵世龙, 孙瑛钦, 华林. 发动机变壁厚变直径管件缩胀成形力学模型与变形规律[J]. 机械工程学报, 2025, 61(14): 352-361.

CHEN Yizhe, SUN Runyuan, ZHAO Shilong, SUN Yingqin, HUA Lin. Study on Mechanical Model and Deformation Characteristics of Tube Upseting-bulging Method on Engine Tubes with Variable Wall Thickness and Diameter[J]. Journal of Mechanical Engineering, 2025, 61(14): 352-361.

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发动机变壁厚变直径管件缩胀成形力学模型与变形规律

Study on Mechanical Model and Deformation Characteristics of Tube Upseting-bulging Method on Engine Tubes with Variable Wall Thickness and Diameter

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