大直径铝合金波纹管复合整体制造工艺研究  

Composite Integrated Manufacturing Process for Large-diameter Aluminum Alloy Bellows

作　　者：周旭东 王家威 冯苏乐[1] 陈哲 邹隆勋 林才渊 初冠南[2] Zhou Xudong;Wang Jiawei;Feng Sule;Chen Zhe;Zou Longxun;Lin Caiyuan;Chu Guannan(Shanghai Aerospace Research Institute of Precision Machinery,Shanghai 201600;School of Materials Science and Engineering,Harbin Institute of Technology(Weihai),Weihai 264209)

机构地区：[1]上海航天精密机械研究所,上海201600 [2]哈尔滨工业大学(威海)材料科学与工程学院,威海264209

出　　处：《航天制造技术》2024年第5期16-23,共8页Aerospace Manufacturing Technology

基　　金：国家自然科学基金(523***48)。

摘　　要：为了得到具有大直径、高膨胀率、低壁厚减薄率的铝合金波纹管,提出了一种复合整体制造工艺,其核心思想是利用搅拌摩擦焊接获得大直径铝合金初始管坯,随后采用轴向压形法成形出所需的连续波形。首先开展平板焊接试验,确定搅拌摩擦焊接最佳工艺参数。通过实验与数值模拟分析结合的方式,基于ABAQUS有限元分析软件,建立了波纹管轴向压形过程的有限元模型,并基于波纹管轴向低压压形过程中的形状精度及壁厚分布情况,分析了不同成形工艺参数对波纹管成形过程的影响,获得了成形内压与轴向进给间最佳的匹配关系。最后开展静力试验考核。结果表明,采用该复合整体制造工艺可以获得满足设计要求的大直径大膨胀率铝合金波纹管,并且具有低成本、高效率优势。In order to obtain aluminum alloy bellows with large diameter,large expansion rate and small wall thickness reduction rate,a composite integral manufacturing process is proposed.The core idea is to obtain the initial tube blank by friction stir welding,and then the required continuous waveform is formed by axial low pressure forming method.Firstly,the plate welding test was carried out to determine the optimum process parameters of friction stir welding.Based on ABAQUS software,the finite element model of the axial low pressure forming method was established.Based on the shape accuracy and wall thickness distribution after the forming method,the influence of different process parameters was analyzed,and the best matching relationship between the forming internal pressure and the axial feed was obtained.Finally,the static test was carried out.The results show that the composite integral manufacturing process can obtain the aluminum alloy bellows with large diameter and large expansion rate that meet the design requirements,and has the advantages of low cost and high efficiency.

关 键 词：轴向压形 搅拌摩擦焊接 铝合金波纹管 工艺参数 复合制造 

分 类 号：V462[航空宇航科学与技术—航空宇航制造工程] TG376[金属学及工艺—金属压力加工]