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

doi:10.3901/JME.2018.09.037

Abstract

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

CLC Number:

TG394

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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