超大直径贮箱箱底整体旋压成形技术

Integral spinning forming technology of storage box bottom with super large diameter

目前,国内大型贮箱箱底采用瓜瓣顶盖拼焊的方法制造,存在制造可靠性不足、生产效率低等问题。针对大型贮箱箱底制造现状,以某型号运载火箭贮箱箱底作为研究对象,设计了先预成形、后旋压成形的工艺方案,并提出了"一道次剪旋+多道次普旋"的旋压工艺方案,通过有限元仿真分析及工艺试验验证了超大直径贮箱箱底整体旋压成形技术的可行性。结果表明:采用预成形方案能够有效抑制零件边缘起皱,采用剪切旋压与普通旋压相结合的成形工艺能够实现箱底的高精度成形。箱底中心区域采用剪切旋压,构件形状可控性好,模具贴合良好;预成形法兰的边缘区域刚度高,采用多道次普通旋压,既能够达到收边贴模的目的,又能够避免边缘减薄量过大的问题。

At present,the large storage box bottom is manufactured by tailor-welding the melon flap top cover in China,which has problems such as insufficient manufacturing reliability and low production efficiency. Based on the current manufacture status of the large storage box bottom,for the storage box bottom for a certain type of carrier rocket,the process scheme of first preforming and then spinning was designed,and the spinning process scheme of "one-pass shear spinning + multi-pass conventional spinning"was proposed. Then,the possibility of integral spinning forming technology for storage box bottom with super large diameter was verified by finite element analysis and process experiments. The results show that the preforming scheme effectively restrains the wrinkling of part edge,and the high precision forming of storage box bottom is realized by the forming process conbinated shear spinning and conventional spinning. In addition,the center area of box bottom adopts shear spinning which has good controllability of component shape and good die fit,and the edge area of pre-formed flange has high rigidity and adopts multi-pass conventional spinning which achieves the purpose of closing and attaching die and avoid the problem of excessive edge thinning.