| 摘要: |
| 为解决传统分块成形-拼焊工艺制造双层薄壁锥壳构件时存在的型面精度低、内外层贴合不严等问题，本文提出一种双层曲母线锥壳构件整体液压成形新工艺。通过控制内压与合模力使内、外层筒坯同步胀形，孪生整体成形出双层锥壳构件。采用数值模拟与实验的方法研究了双层曲母线锥壳构件液压成形的贴模过程，并对最终获得的双层锥壳构件的型面轮廓精度及壁厚分布规律进行了分析。结果表明：整体液压成形过程中内、外层锥形筒坯同步发生变形，在凹模型腔两端率先贴模，之后随着内压增大开始从大端向小端逐渐贴模。双层锥壳构件型面直径偏差控制在[-0.5 mm, +1.5 mm]以内，最大偏差发生在大端。此外，液压成形过程中双层锥形筒坯大端发生缩径变形并流入型腔，产生自补料作用缓解构件壁厚减薄，最大壁厚减薄率为3.68%。 |
| 关键词: 双层锥壳构件 液压成形 尺寸精度 曲母线 |
| 基金项目:中国博士后科学基金（2023****158）；黑龙江省自然科学基金（LH2****057） |
|
| Research on Integral Hydroforming Process of Double-layered Conical Shell Component with Curved Generatrix |
|
Zhu Yuanpu1,2, Cui Xiaolei1,2, Yuan Shijian1,2, Liu Gang1,2
|
|
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
|
| Abstract: |
| To solve the problems of low profile accuracy and loose fitting of inner and outer layers during the traditional block-forming and welding process for manufacturing double-layered thin-walled conical shell components, a new integral hydroforming process of double-layered conical shell component with curved generatrix is proposed in this paper. By controlling the internal pressure and clamping force, both the inner and outer conical shells are simultaneously bulged, and a double-layered conical shell component is formed as a whole by twinning. The behavior of the double-layered conical shell in contact with the die cavity during the hydroforming process was studied by numerical simulation and experiment. The profile accuracy and the thickness distribution of a double-layered conical shell component were analyzed. The results indicated that the inner and outer layers of the double-layered conical shell were deformed simultaneously. The double-layered conical shell was first fitted to the terminal of the die cavity, and then it gradually was fitted to the die cavity from the large end to the small end with the increase of internal pressure during the hydroforming process. The profile diameter deviation of a conical shell component was controlled within [-0.5 mm, +1.5 mm], and the largest diameter deviation occurred on the large end. In addition, a shrinking deformation occurred on the large end of the double-layer conical shell component. The large end with shrinking deformation was fed into the die cavity during the hydroforming process, which generated self-feeding effect to restrain the thinning of thickness, the maximum thickness thinning rate was 3.68%. |
| Key words: double-layered conical shell component hydroforming dimensional accuracy curved generatrix |
