某大型空间航天器带法兰异构壁板精密成形工艺研究

Research on Precision Forming Technology for Large Integeral Panel with Flanges of a Spacecraft

针对某大型空间航天器带法兰异构壁板薄厚不一致、刚度不均匀、在成形过程中容易产生断裂的难题,利用ABAQUS对整体壁板压弯成形过程进行了有限元分析,讨论了直接压弯成形过程中易产生缺陷的部位和原因。结果表明,壁板直接压弯成形加强筋及其交汇处应力集中,应力值最大,为成形过程的薄弱区,容易产生失稳及断裂。针对该情况,提出了柔性补强压弯成形工艺方法,并进行了成形工艺实验验证,实验结果表明,采用该方法成形的壁板蒙皮与加强筋表面质量良好,曲率均匀,无缺陷,满足尺寸精度要求;最后,在有限元模拟及工艺验证实验的基础上,利用柔性补强技术和分段压弯成形技术相结合的方法,解决了带法兰异构壁板传统成形法兰过渡处易断裂的成形难题,实现了该大型空间航天器多种带法兰异构壁板的成形制造。

Integral panels with different flanges are difficult to form and easy to fracture during the forming process due to their different uniform thickness and stiffness. To solve this problem,press bending process of the integral panel with different flanges was simulated with the ABAQUS software. The defection and position of the defection were analyzed. The results indicated that the stress concentrated in the strengthening ribs and the intersections among the strengthening ribs when the integral panels were pressed bending. Press bending experiments were carried out using lactoprene wad flexible strength compensation forming technology and the method was proved to be effective.The integral panels were formed accurately with this method. The quality of the skin and the strengthening ribs of the integral panels after forming was in good state and without any defections.The design precision was satisfied. On this basis,the technology combining the flexible strength compensation with the subsection press forming was proposed which had the advantages of universal property and large deformability force. Therefore,the problem that the integral panels with flanges were difficult to form and easy to fracture has been solved and various integral panels with flanges of a spacecraft have been manufactured.