航空异形截面导管内高压整体成形工艺分析

Analysis of integral hydroforming process in irregular section aviation tube

针对航空领域异形截面焊接导管面临的成形精度低、生产效率差且成本高等问题,以某异形截面导管零件作为研究目标,提出基于内高压成形的导管整体成形工艺方法。通过采用无内压预压弯成形、内高压压弯胀形和液压锻造整形3道成形工序对零件进行成形,通过有限元模拟和实验验证了所提出的工艺设计的可行性。研究结果表明:提出的基于内高压成形的导管整体成形工艺方法可以实现某航空异形截面导管整体成形,成形质量优异,最大减薄率6%,为此类航空异形截面导管的整体精密成形提供了可靠的技术支撑。

In order to solve the problems of low forming accuracy,poor productivity and high cost faced by welded tubes with irregular cross-section in the aerospace field,a catheter integral forming process method based on internal high pressure forming is proposed.In this paper,an irregular section aviation tube is set as the research target,three forming processes(pre-bending without internal pressure,hydraulic bending and bulging and hydro-forging)are proposed,and the feasibility of the proposed process design is verified through finite element simulation.Finally,through the experimental study of the hydroforming forming process,the integral forming of irregular section aviation tube is realized with excellent forming quality and a maximum thinning rate of 6%,which provides reliable technical support for the integral precision forming of this kind of irregular section aviation tube.