铝合金薄壁波纹板充液成形工艺研究

Hydroforming Process of Aluminum Alloy Thin-wall Corrugated Sheet

目的解决航空铝合金薄壁波纹板爆炸成形工艺成形效率低且成形质量差的问题。方法提出了3种充液成形工艺方案,利用有限元分析软件对3种成形方案进行了对比分析,并且对最优方案进行了试验验证。结果有限元分析结果显示,双面加压充液成形方法能够使零件的各部分变形均匀,避免了在充液成形过程中因摩擦力作用导致的局部变形过大产生的开裂,有效地提高了材料的成形能力。结论双面加压充液成形方法能够成形出轮廓精度高、表面质量好的铝合金薄壁波纹板。

In order to overcome the issues of low efficiency and poor surface quality of aluminum alloy thin-walled corrugated sheet during explosively forming projectile（ EFP）,three active hydroforming process schemes were put forward to substitute EFP. FEM simulations were conducted to comparatively analyze these schemes,and the optimal scheme was validated by experiment. The FEM and experimental results showed that the active hydroforming process of bulging the blank side by side was able to produce uniform deformations with improved wall thickness / forming capacity and could prevent the rupture failure due to local excessive deformation caused by friction. This new method could produce the aluminum alloy corrugated sheet with high precision and high surface quality.