大尺度非均质壳体流体压力成形机制与缺陷控制方法

Mechanism and Defects Control of Fluid Pressure Forming for Large-sized Inhomogeneous Shell

本文介绍了国家自然科学基金航天先进制造技术研究联合基金项目(U1637209)的主要进展与标志成果。针对新一代运载火箭对箱底整体制造的迫切需求,围绕非均质曲面壳体整体成形塑性失稳机制和缺陷控制的核心科学问题,开展了拼焊板液压胀形性能测试,通过失稳应力分析、箱底成形仿真、工艺实验及测试等,揭示流体载荷作用下非均质薄壳复杂变形行为与失稳机理,发明可控加压流体高压成形技术,解决了非均质薄壳起皱和开裂并存的国际性难题,突破了厚径比的极限边界,并在国际上首次采用与构件近等厚的拼焊薄板直接整体成形出3m级箱底,解决了箭体整体结构制造的重大瓶颈难题。

The progress and achievements of the project supported by NSFC(U1637209)are introducted in this paper.Aiming to the urgent demand on integrated manufacture of tank dome for new generation launch vehicles,and the problem on plastic instability of inhomogeneous shell during integrated forming process,the complicated deformation behavior and instability mechanism of the tailored blank under fluid pressure were revealed.The technology of controllable fluid pressure forming process was invented,which was used to overcome the worldwide challenges on co-occurrence of bursting and wrinkling defects and the limit boundary of thickness to diameter ratio was exceeded.A dome of 3 meter in diameter was deformed in the world by the first time using tailored blank with thickness close to the component,which solves the key issues on the manufacture of integrated structure for launch vehicle.