薄壁深腔件部分阴模充液成形技术研究

Research on failure control of hydroforming for thin-walled and deep cavity components

充液成形技术能有效解决复杂零件的成形问题.针对某飞机薄壁深腔蒙皮常规拉深成形需要多道次成形、成形质量差的问题,通过分析充液成形过程中易出现的失稳,设计了带部分阴模的一模两件充液成形的技术方案.结合数值模拟,对薄壁深腔件充液成形过程中出现的悬空区失稳形式进行了研究,优化了液室压力加载曲线、压边间隙、初始反胀压力等工艺参数.结果表明,薄壁深腔件在带部分阴模的一模两件的工艺方案下,能有效避免悬空区的起皱,同时改善了一模一件补充段的破裂问题,提高了零件成形极限和壁厚分布的均匀性.

Hydroforming can effectively sovle the forming problem of complicated components. Aiming at the difficulty of one-stage forming problem and poor forming quality for common deep drawing of an ariplane thin- walled and deep cavity coating component, hydroforming of double-cavity with partial-die proposal is designed by analysising defects during hydroforming. Combined with numerical simulation, defects of noncontact region during coating component forming are studied. Cavity pressure loading path, blankholder gap, prebulge pressure and prebulge height are also optimized. The results show in the process schem of double-cavity with partial- die, noncontact region wrinkle and supplyment segment fracture of one-cavity process sehem can be avoided , while forming limit and the uniformity of thickness can be enhanced.