2195铝锂合金贮箱球底充液拉深成形起皱缺陷演变规律数值模拟研究  

Numerical Simulation of the Evolution of Wrinkling Defects in the Hydromechanical Deep Drawing Process of the 2195 Al-Li Alloy Spherical Tank Dome

作　　者：张志超 堵同亮 富芳艳 胡蓝 申世军 洪吉庆 刘伟[2] 徐永超[2] 郭立杰 苑世剑[2] ZHANG Zhichao;DU Tongliang;FU Fangyan;HU Lan;SHEN Shijun;HONG Jiqing;LIU Wei;XU Yongchao;GUO Lijie;YUAN Shijian(Shanghai Aerospace Equipments Manufacturer Co.,Ltd.,Shanghai 200245,China;School of Materials Science and Engineering,Harbin Institute of Technology,Harbin 150001,Heilongjiang,China)

机构地区：[1]上海航天设备制造总厂有限公司,上海200245 [2]哈尔滨工业大学材料科学与工程学院,黑龙江哈尔滨150001

出　　处：《上海航天（中英文）》2024年第4期76-88,共13页Aerospace Shanghai（Chinese&English）

基　　金：上海市青年科技启明星计划(21QB1402100);上海市科技创新行动计划优秀学术带头人计划(21XD1431800)。

摘　　要：为满足登月着陆器舱体高可靠性、轻量化制造需求,提出贮箱球底充液拉深成形方法。对于直径3350 mm的2195铝锂合金箱底,相对2219和5A06铝合金,材料塑性差,成形易开裂失效,且整底成形厚径比仅为2.5‰,易起皱失稳。针对上述问题,建立了整底充液拉深成形仿真模型,进行不同液室压力、压边力条件下的数值模拟,讨论整底充液拉深成形变形规律,分析整底成形缺陷形式及控制方法,优化整底充液拉深液室压力加载路径,获得球底壁厚分布规律。结果表明:拉深行程达0.24H(H为零件最终高度)时,球底悬空区域为典型的压缩应力状态,产生了沿母线方向的起皱缺陷环向均布12个,拉深行程0.79H时,环向起皱数量倍增;引入液室压力后使悬空区由压缩应力状态转变为拉伸应力状态,从而避免了悬空区起皱缺陷的发生;压边力和液室压力对悬空区应力状态影响显著,随着压边力增大,球底壁厚减薄趋势增大,而随着液室压力的增大,球底壁厚减薄趋势减弱;球底拉深试验对初始壁厚9.5 mm板材,采用2.5×10^(7)N压边力、8 MPa液室压力加载路径时,壁厚最大减薄率为7.4%,壁厚分布均匀,无起皱缺陷。In order to meet the manufacturing requirements of high reliability and lightweight for lunar lander tanks,a hydromechanical deep drawing process is proposed for forming spherical tank domes.Compared with the Alluminum alloy of 2219 and 5A06,2195 Al-Li alloy has a poor plastic deformation ability.Also,the ratio of thickness verse diameter of blank is 2.5‰,which leads to a difficult in the hydroforming of tank dome with a diameter of 3350mm.To solve the forming defects of crack and wrinkling,the simulation model is established with the new generation of 2195 Al-Li alloy,and the simulation tests under different values of liquid chamber pressure and binding force are carried out.The deformation rules are discussed,the forming mechanisms and control methods of defects are analyzed,the path of loading pressure in the forming process of tank dome is optimized,and thus the thickness distribution of the tank dome is obtained.The results show that,during the forming process without the liquid chamber pressure,the floating area of the blank subjects to a severe compressive hoop stress and 12 wrinkles exist along the longitude direction when the punch stroke reaches 0.24H,and the number of wrinkles is doubled when the punch stroke increases to 0.79H.However,during the forming process with the liquid chamber pressure,the introduction of the liquid chamber pressure makes the floating area change from a compressive stress status to a tensile stress status,which avoids the occurrence of wrinkles.Moreover,the effects of the binding force and liquid chamber pressure on the floating area are significant.The decrease tendency of the tank dome thickness increases with the increase in the binding force,while decreases with the increase in the liquid chamber pressure.The experiment on a blank with the initial wall thickness of 9.5 mm shows that,under the binding force of 2.5×10^(6) N and the liquid chamber pressure of 8 MPa,the maximum thickness thinning rate is 7.4%,the thickness distribution is uniform,and there is no wrinkling d

关 键 词：2195铝锂合金 直径3350 mm球底 充液拉深 起皱缺陷 极限厚径比2.5‰ 型面精度 

分 类 号：TN911.73[电子电信—通信与信息系统] TP391.9[电子电信—信息与通信工程]