某薄壁壳体精密成形工艺数值模拟

Numerical Simulation of Precision Forming Process for a Thin-walled Shell

某异形壳体尺寸大、材料昂贵,材料利用率仅10%左右,加工成本居高不下。为提高材料利用率,在分析其结构特点的基础上,设计了新的成形工艺方案:下料-底部成形-薄壁成形-拉深-机加。在底部成形过程中分别设计了冲孔-翻孔-挤压法和连皮法;在薄壁成形时以减小加工余量的方式提高材料利用率。利用数值模拟方法,分析不同方案、不同坯料厚度及不同部分成形过程中的行程载荷、等效应力等,根据实际条件选择合适的工艺方案,最终使其材料利用率提高了4倍。

The processing cost of a special shaped shell is high as a result of large size,expersive material and only about 10%in material utitization.In order to improve the utilization rate of materials,a new forming scheme was designed based on its structural characteristics:blanking-bottom forming-thin wall part forming-deep drawing-mechanical processing.In the process of bottom forming,the punching-turning-squeeze method and even skin method were designed,respectively.In thin wall forming,the material utilization rate could be improved by reducing machining allowance.Using numerical simulation method to analyze the load,equivalent stress in different solutions,different blank thickness and different part,appropriate process was chosen according to the practical conditions to improve the material utilization by 4 times.