涡扇发动机异形曲面壳体零件整体成形工艺

涡扇发动机异形曲面壳体零件单位长度直径变化较大,传统的制造方法是采用分体成形、组合焊接工艺,所需工序多、质量控制环节多、使用可靠性差,采用粘性介质压力整体成形方法则可以较好地解决这一问题。通过有限元模拟和试验方法,分析了成形工步、粘性介质粘性附着应力对板材流动及壁厚变化的影响。研究结果表明,粘性介质压力成形可以控制变形区板材的流动,提高成形试件壁厚分布的均匀性,使直径比为1.38零件的壁厚减薄率控制在12%,适合于涡扇发动机异形曲面壳体零件的整体成形。

Integral forming for special-shaped curved surface shell parts of turbofan engine

The special-shape curved surface shell parts of turbofan engine,which vary greatly in diameter,are usually manufactured by forming decomposed parts and then assembling them through welding.The traditional forming technology has some disadvantages,such as requirement of multi-forming-step,high cost and low accuracy,which can be overcome by viscous pressure integral forming process.Through numerical simulation and experiments,the effects of forming steps and the tangent adhesive stress of viscous medium on the material flow and wall thickness variation are analyzed.Research results show that the deformed sheet metal flow can be controlled efficiently and the homogeneity of wall-thickness of formed part is improved through viscous pressure forming(VPF).The wall-thickness thinning is less than 12% for the parts with 1.38 diameter ratio.So VPF is very suitable for integral forming of the special-shape curved surface shell parts of turbofan engine.