复杂薄壁零件板多级充液成形及过程数值模拟

板充液成形已被证明是制造复杂零件一种有效的方法.采用板多级充液成形方法对难成形复杂薄壁结构的飞行器零件进行了研究,利用有限元数值模拟的方法,分析了预成形凸模形状、预成形深度,以及液室压力等关键工艺参数对成形的影响.对成形中出现的诸如破裂、起皱等失效形式进行了探讨,给出了终成形时实现成功成形的最高液室压力区域范围.提出了控制成形质量的措施,优化了工艺参数,并根据数值模拟的结果进行了试验验证.结果表明,模拟结果和试验结果达到了较好的一致. 

Multi sheet hydroforming of complicated thin wall part and numerical simulation

Sheet hydroforming has proven to be an effective method for manufacturing complicated parts.The multi-sheet hydroforming technology of complicated thin wall aerocraft part was investigated.Effects of key process parameters including the shape of pre-forming punch,corresponding pre-forming depth,and cavity pressure on the forming process of the finally formed parts were explored in multi-hydrodynamic deep drawing by using the finite element numerical simulation methods.Failure types including fracture and wrinkling during sheet hydroforming were discussed.The successful region of the maximal cavity pressure was provided during the forming process of the final formed parts.The measures of controlling forming quality were presented,and process parameters were optimized.According to the results of the numerical simulation,the experimental confirmations were carried on by using the equipment of sheet hydroforming which had been developed independently.It is shown that the results from the simulation are in reasonable agreement with those from experiment.