铝合金大型薄壁异型曲面封头旋压成形研究进展

doi:10.3901/JME.2018.09.086

摘要/Abstract

摘要： 大型薄壁异型曲面整体构件是航天航空等重要领域迫切需要的高性能轻量化构件。旋压和淬火是实现该类构件整体化制造和性能控制的一种有效途径。然而，大型薄壁异型曲面旋压是多因素耦合作用下的多道次局部加载/卸载复杂过程，成形过程中易出现局部损伤破裂、起皱、隆起、不贴模等缺陷，且旋压后的淬火过程还易造成大的残余应力和淬火变形，并决定着构件的最终使用性能。在建立大型薄壁异型曲面构件旋压和淬火全过程有限元模型的基础上，分析大型薄壁异型曲面构件旋压过程中应力应变分布与变化规律；研究失稳起皱缺陷的形成机理，获得旋压工艺参数对薄壁壳体凸缘周向压应力的影响规律，提出控制凸缘起皱的方法；研究板坯尺寸波动对成形质量的影响；研究获得大型薄壁异型曲面封头旋压件淬火残余应力分布规律和淬火变形规律。

关键词: 大型薄壁异型曲面, 多道次复合旋压, 封头旋压件淬火, 铝合金, 旋压和淬火全过程有限元建模

Abstract: Large-sized thin-walled and special-curved surface heads are the urgent needs of aerospace and aviation industry for its high-performance and lightweight. Spinning-quenching is one effective integral forming process to manufacture these components. However, the spinning of large-sized thin-walled and special-curved surface head is one of the complicated local loading/unloading processes under the action of multi-parameters and their coupled effects. In this process, the heads are very prone to produce forming defects, such as local damage rupture, flange wrinkling, local bulge, and unfitting. Additionally, the quenching treatment after spinning will lead to heavy quenching distortion and residual stress, thus seriously deteriorate the material performance. In this work, a finite element model for the whole process of spinning-quenching are established. Based on the model, the distribution and evolution of stress and strain field of the large-sized thin-walled and special-curved surface heads during spinning process is analyzed. In order to obtain the effect laws of process parameters on flange circumferential compressive stress, the mechanism of flange wrinkling is investigated, and a method of controlling the flange wrinkling is proposed. The effect laws of the thickness variation of slabs on deformation quality are investigated. The quenching residual stress and distortion of the large sized thin-walled and special-curved surface heads are also studied.

Key words: aluminium alloy, large-sized thin-walled and special-curved surface spinning head, multi-pass compound spinning, quenching for spinning head, simulation for whole process of spinning and quenching

中图分类号:

TG302

詹梅, 李志欣, 高鹏飞, 马飞, 李锐, 崔笑蕾, 张洪瑞, 陈淑婉. 铝合金大型薄壁异型曲面封头旋压成形研究进展[J]. 机械工程学报, 2018, 54(9): 86-96.

ZHAN Mei, LI Zhixin, GAO Pengfei, MA Fei, LI Rui, CUI Xiaolei, ZHANG Hongrui, CHEN Shuwan. Advances in Spinning of Aluminum Alloy Large-sized Thin-walled and Special-curved Surface Head[J]. Journal of Mechanical Engineering, 2018, 54(9): 86-96.

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