超薄不锈钢波纹管液压成形力学分析与工艺研究  

Mechanics analysis and process research on hydroforming of ultra-thin stainless steel bellows

作　　者：陈一哲 鲁栋 马小瑶 洪峰[1] 赵世龙 王辉[1,2] 华林[1] Chen Yizhe;Lu Dong;Ma Xiaoyao;Hong Feng;Zhao Shilong;Wang Hui;Hua Lin(Hubei Key Laboratory of Advanced Technology for Automotive Components,Wuhan University of Technology,Wuhan 430070,China;Hubei Longzhong Laboratory,Wuhan University of Technology,Xiangyang 441000,China)

机构地区：[1]武汉理工大学现代汽车零部件技术湖北省重点实验室,湖北武汉430070 [2]武汉理工大学湖北隆中实验室,湖北襄阳441000

出　　处：《锻压技术》2024年第7期179-189,共11页Forging & Stamping Technology

基　　金：中国科协青年人才托举工程(2021QNRC001);国家自然科学基金资助项目(52175360,52373320)。

摘　　要：超薄不锈钢波纹管具有优异的弹性性能,但超小厚径比、圆角半径等特征导致其成形过程中易发生破裂、屈曲等缺陷,制约了其在汽车领域的发展与应用。通过理论分析建立了薄壁波纹管在自由胀形、内压力与轴向力共同作用下的力学模型,发现了不同应力、应变状态下内压力的上下限以及内压力与胀形波高的关系。通过试验与数值模拟相结合的方式,研究了初胀内压力、整形内压力与加载路径对薄壁波纹管成形质量的影响。采用最优工艺参数,得到的波纹管平均外径为Φ70.7 mm,误差小于2%,验证了力学分析与数值模拟的准确性,为汽车关键零部件的制备提供了参考。Ultra-thin stainless steel bellows exhibit exceptional elasticity,however,their inherent low thickness-to-diameter ratio and fillet radius lead to a higher susceptibility to defects such as fractures and buckling,thereby impeding their advancement and widespread adoption within the automotive industry.A mechanical model for thin-walled bellows under the combined action of free bulging,internal pressure and axial force was established through theoretical analysis.And the upper and lower limits of intermal pressure,and the relationship between internal pressure and height of bulging wave under different stress and strain states were found.Experimental and numerical simulation were synergistically employed to investigate the influence of initial expansion internal pressure,shaping internal pressure and loading paths on the forming quality of thin-walled bellows.The bellows obtained by the optimal process parameters,with an average outer diameter ofΦ70.7 mm,exhibits an error margin below 2%,validating the accuracy of both the theoretical analysis and numerical simulations,this validation serves as a valuable reference for the fabrication of critical automotive components.

关 键 词：波纹管 液压成形 力学模型 内压力 加载路径 

分 类 号：TG394[金属学及工艺—金属压力加工]