薄壁小半径弯头弯胀成形数值模拟技术研究  

Numerical simulation research on bend-bulge forming of thin-walled elbow with small bending radius

作　　者：郎利辉[1] 罗璇[1] 程鹏志[1] 訾燕[2] 周勇[2] 王韬 武海 

机构地区：[1]北京航空航天大学机械工程及自动化学院,北京100191 [2]中航工业沈阳黎明航空发动机(集团)有限责任公司,辽宁沈阳110043 [3]上海汇众汽车制造有限公司,上海200122

出　　处：《锻压技术》2014年第12期45-52,共8页Forging & Stamping Technology

基　　金：国家自然科学基金资助项目(1175024)

摘　　要：针对现代技术无法直接成形的相对弯曲半径r/D≤1、相对壁厚t/D≤0.05的弯头零件,提出了一种弯胀成形工艺。该工艺将数控弯管技术与充液成形技术相结合,旨在消除传统半管对焊工艺中的焊缝,实现薄壁小半径弯头的整体成形。采用全过程数值分析方法和正交试验方法,研究了弯胀成形工艺的可行性以及关键参数的选取问题。研究结果表明,数控弯管技术使零件的预成形快速且稳定,充液成形技术有效提高了零件的成形极限,弯胀成形工艺对薄壁小半径弯头的制造行之有效。A Bend-bulge Forming （BBF） process was put forward for elbow parts with relative bending radius r/D ≤ 1 and relative wall thickness t/D≤0. 05, which cannot be formed directly with available technologies. BBF combining CNC bending technology and hydroforming technology realizes the forming of thin-walled elbows with small bending radius which eliminates welding lines of traditional halfpipe butt welding process. The feasibility of BBF and selection of key parameters were studied by the numerical simulation of overall process and orthogonal experiment method. The research results show that CNC bending technology is a rapid and stable way for preforming. At the same time, hydroforming technology increases the forming limitation of parts effectively, and BBF is a good method to manufacture thin-walled elbows with small bending radius.

关 键 词：薄壁小半径弯头 数控弯管 充液成形 弯胀成形 数值模拟 

分 类 号：TG306[金属学及工艺—金属压力加工]