充液成形技术在航天火箭整流罩成形中的应用

Application of Hydroforming Technology in Aerospace Rocket Fairing Forming

基于充液形成工艺的航天火箭整流罩零件,通过数值模拟的分析与试验结果进行对比,证明了数值模拟可以给试验提供正确方向,也说明数值模拟的准确性。根据现场的试验情况,基于实际制件过程出现的一些缺陷,调整液室压力与压边力加载曲线,根据零件的拉深高度进行合理匹配,最后达到控制整个冲液成形过程的起皱和破裂的问题。实现了充液拉深工艺在大尺寸薄壁整流罩构件上的工艺升级,大大提升了零件的表面质量,从而可以解决传统落压工艺的多道次拉深工序、多道次退火及多道次敲修导致的零件变形与表面质量差等问题,从而保证零件在生产过程中表面质量和成形精度的控制。

Aiming at the hydroforming process of large-scale thin-walled fairing,wrinkle-free and crack-free parts were obtained by numerical simulation.The numerical simulation results were in good agreement with the experimental results,and the accuracy and applicability of numerical simulation were verified.Through field tests,the formation mechanism and control mode of defects were studied.The wrinkling and cracking defects in hydroforming process were solved by loading curve of blank holder force,controlling initial chamber pressure and blank holder force.The process upgrading of liquid-filled deep drawing on large-scale thin-walled fairing components is realized,the product profile accuracy is greatly improved,the manual dressing and annealing processes in the later stage of down-pressing forming are eliminated,and the product quality and production efficiency are guaranteed.