非焊接壁板密封舱多道次旋压整体制造研究

Study on Integrated Manufacturing Technology of Non-welded Spacecraft Structure with Multi-pass Spin-forming

针对非焊接航天器舱体结构载荷环境和结构功能集成设计要求,研究了非焊接的大深径比铝合金双锥面结构的多道次旋压整体制造技术。通过ABAQUS仿真和工艺试验件制备获得了大深径比铝合金双锥面结构整体成形关键工艺参数;并对比得出直线轨迹加载方案中各道次材料变形量可控,方案较优;指出了在多道次柔性旋压成形过程中,除旋轮接触点受力变形外,板坯末端是成形缺陷高风险区,易发生翘曲;若变形量可控则产生的波浪和起皱在后道次工艺过程中可消除;最终完成了5B70密封舱缩比工艺试验件的制造。结果表明,多道次柔性旋压成形用于非焊接航天器舱体结构整体制造的可行性得到了验证,解决了金属流线连续、传力路径无间断、基于最优传力路径的非焊接壁板密封舱整体制造难点,可降低航天器结构整体制造时设备吨位,节约模具设计和制造成本,为未来轻量化、长寿命、可重复使用的深空探测飞行器或载人飞行器整体制造技术提供参考。

According to the load environment and the integrated design requirements of structural function of the non-welded spacecraft cabin structure,the multi-pass spin-forming technology of non-welded aluminum alloy double cone structure was studied.The key process parameters of the integral forming structure with large depth to diameter ratio were obtained through simulation and test specimen manufacture.First,comparing the linear trajectory with the curved trajectory,the parameters of the linear trajectory loading scheme were optimized by ABAQUS numerical models.It was found that in the multi-pass flexible spinning process,the contact point of the roller and the skirt of blank had large deformation and thus bends or curves occurred easily.If the warp deformation was small and controllable,the waves and wrinkles could be eliminated in the later pass process.Then a scaling-down 5B70 cabin was manufactured.In this paper,the multi-stage flexible spinning technology was verified to be feasible for non-welded spacecraft cabin structure.The problem of continuous metal streamline and uninterrupted force transmission path of the non-welded spacecraft structure was solved.The multi-step spinning technology could effectively reduce the tonnage of equipment and save the cost of mold design.It may provide reference for the overall manufacturing technology of lightweight,long life,reusable robotic or manned spacecraft for deep space exploration.