推进剂贮箱零件侧翻孔电磁成形数值模拟

Numerical simulation on the side hole flanging electromagnetic forming for propellant tank parts

基于ANSYS多物理场耦合模块,采用松散耦合法,建立了推进剂贮箱零件侧翻孔电磁成形的有限元模型,揭示了坯料电磁力、应力、应变和厚度等的分布规律及其随时间变化规律,并优化了放电电压和成形线圈内径等工艺参数。分析结果表明:坯料在圆角区域应力和应变较大,且厚度减薄量较大;坯料圆角处残余应力较大。放电电压增大,坯料变形量增加,但厚度减薄量相应增加;线圈内径增大,坯料与模具最大间隙、最大夹角以及坯料最小厚度均先减小后增大。得到的放电电压和成形线圈内径优化值分别为40 kV和40 mm。

A finite element model of the side hole flanging for propellant tank parts in the electromagnetic forming process was established based on the multi-physics coupling module and the loose coupling method,and the distribution of the electromagnetic force,stress,strain and thickness of the blank and their variations with time were revealed. Furthermore,the process parameters of the discharge voltage and the coil inner diameter were optimized. The analysis results show that the stress and strain of blank are bigger at the round corner area with a larger thickness reduction and a larger residual stress at the round corner area. With the increase of the discharge voltage,the deformation of blank increases,while the thickness reduction increases correspondingly. As the coil inner diameter increases,the maximum clearance and the maximum angle between die and blank,and the minimum thickness of the blank decrease firstly and then increase. Finally,the optimum values of the discharge voltage and the coil inner diameter are 40 k V and 40 mm respectively.