带筋回转件旋压成形坯料反向设计与制备工艺

张渝; 何嘉宁; 越豪杰; 蒋国保; 陈真一

doi:10.3969/j.issn.1674-6457.2025.09.022

PDF(4582 KB)

精密成形工程 ›› 2025, Vol. 17 ›› Issue (9) : 222-232. DOI: 10.3969/j.issn.1674-6457.2025.09.022

先进制造技术与装备

带筋回转件旋压成形坯料反向设计与制备工艺

张渝^*, 何嘉宁, 越豪杰, 蒋国保, 陈真一

作者信息 +

Reverse Design and Preparation Process of Slab for Spinning Forming Rotary Part with Ribs

ZHANG Yu^*, HE Jianing, YUE Haojie, JIANG Guobao, CHEN Zhenyi

Author information +

文章历史 +

摘要

目的研究用于旋压成形带筋回转件的坯料制备工艺及旋压过程中的壁厚均匀性问题。方法首先,通过有限元软件分析带筋回转件旋压成形规律,反向设计径向TRB板坯结构;其次,采用正交试验和极差方法,研究坯料结构参数对成形件壁厚均匀性的影响;最后,结合建立的Kriging近似模型与NSGA-Ⅱ算法对坯料结构参数进行多目标优化。结果对于使用等厚板坯旋压制出的带筋回转件,中段材料在拉应力和加工硬化作用下减薄明显,正交试验结果表明,结构参数按对壁厚均匀性的影响由大到小的顺序依次为厚区高度、转折点高度、AC过渡区长度、AB过渡区长度、DE过渡区长度;使用多目标优化得到坯料结构参数的最优解,对比后预测误差控制在5%以下。结论可使用径向TRB板坯对旋压成形锥形回转件材料减薄进行补偿使其趋于目标壁厚。采用Kriging近似模型并结合NSGA-Ⅱ算法进行多目标优化得到的最佳坯料参数准确度较高,可提高带筋回转件壁厚均匀性优化效率。优化后的成形件最大减薄率下降了20.6%,最大壁厚差减少了0.544 mm,平均壁厚偏差率下降了9.74%,壁厚均匀性有了明显提升。

Abstract

The work aims to study the preparation process of slabs used for spinning forming rotary parts with ribs, and the thickness uniformity during spinning. Firstly, the spinning forming law of rotary parts with ribs was analyzed by the finite element software, and the radial TRB slab structure was designed in a reversed direction. Secondly, the influence of the slab structural parameters on wall thickness uniformity was researched by orthogonal test and range method. Finally, the established Kriging approximation model and NSGA-II algorithm were combined to perform multi-objective optimization of the slab structural parameters. The middle section material of spinning forming rotary parts with ribs was thinned obviously under the action of tensile stress and work hardening by using equal thickness slabs. The orthogonal test results showed that the order of influence of the slab structural parameters on the thickness uniformity of the forming part was thick zone height, turning point height, AC transition zone length, AB transition zone length, DE transition zone length. The optimal solution of the slab structural parameters was obtained by multi-objective optimization. After comparison, the prediction error was controlled below 5%. The radial TRB slab can be used to compensate the material thinning of spinning forming conical rotary parts to the target wall thickness. The optimal slab parameters obtained by Kriging approximation model combined with the NSGA-II algorithm for multi-objective optimization have high accuracy, which can improve the efficiency of thickness uniformity optimization of rotary parts with ribs. After optimization, the maximum thinning rate of the forming part is reduced by 20.6%, the maximum thickness difference is reduced by 0.544 mm, the average thickness deviation rate is reduced by 9.74%, and the thickness uniformity is significantly improved.

导出引用

张渝, 何嘉宁, 越豪杰, 蒋国保, 陈真一. 带筋回转件旋压成形坯料反向设计与制备工艺[J]. 精密成形工程. 2025, 17(9): 222-232 https://doi.org/10.3969/j.issn.1674-6457.2025.09.022

ZHANG Yu, HE Jianing, YUE Haojie, JIANG Guobao, CHEN Zhenyi. Reverse Design and Preparation Process of Slab for Spinning Forming Rotary Part with Ribs[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 222-232 https://doi.org/10.3969/j.issn.1674-6457.2025.09.022

中图分类号： TG386

参考文献

[1] 林忠钦, 于忠奇, 戴冬华, 等. 复杂高筋薄壁构件旋压-增材复合制造技术发展与展望[J]. 航空学报, 2023, 44(9): 627493.
LIN Z Q, YU Z Q, DAI D H, et al.Development and Prospect of Metal Spinning: Additive Hybrid Manufacturing Technology for Complex Thin-Walled Component with High Ribs[J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(9): 627493.
[2] 王博, 郝鹏, 田阔. 加筋薄壳结构分析与优化设计研究进展[J]. 计算力学学报, 2019, 36(1): 1-12.
WANG B, HAO P, TIAN K.Recent Advances in Structural Analysis and Optimization of Stiffened Shells[J]. Chinese Journal of Computational Mechanics, 2019, 36(1): 1-12.
[3] 雷煜东, 詹梅, 樊晓光, 等. 带筋薄壁构件成形制造技术的发展与展望[J]. 西北工业大学学报, 2022, 40(1): 1-17.
LEI Y D, ZHAN M, FAN X G, et al.A Review on Manufacturing Technologies of Thin-Walled Components with Ribs[J]. Journal of Northwestern Polytechnical University, 2022, 40(1): 1-17.
[4] XIA Q X, XIAO G F, LONG H, et al.A Review of Process Advancement of Novel Metal Spinning[J]. International Journal of Machine Tools and Manufacture, 2014, 85: 100-121.
[5] 宋金龙, 赵亦希, 于忠奇, 等. 铝合金封头旋压成形变厚度毛坯设计方法[J]. 上海交通大学学报, 2017, 51(11): 1304-1311.
SONG J L, ZHAO Y X, YU Z Q, et al.Research on Design Method of Variable Thickness Blanks for Aluminum Alloy Head Spinning Forming[J]. Journal of Shanghai Jiao Tong University, 2017, 51(11): 1304-1311.
[6] 吕伟, 詹梅, 王鹏, 等. 带螺旋内筋薄壁筒形件旋压变形特征[J]. 宇航材料工艺, 2021, 51(4): 104-108.
LYU W, ZHAN M, WANG P, et al.Deformation Mechanism in Flow Forming of Thin-Walled Tube with Helical Grid-Stiffened Ribs[J]. Aerospace Materials & Technology, 2021, 51(4): 104-108.
[7] 李萍, 胡传鹏, 杨卫正, 等. 带横向外凸筋多楔轮旋压成形规律及工艺研究[J]. 哈尔滨工业大学学报, 2018, 50(11): 153-159.
LI P, HU C P, YANG W Z, et al.Study on Spinning Forming Process of Multi-Wedge Belt Pulley with Transverse Outer Ribs[J]. Journal of Harbin Institute of Technology, 2018, 50(11): 153-159.
[8] 江树勇, 张艳秋, 赵立红, 等. 基于不同减薄量的纵向内筋薄壁筒反向滚珠旋压分析[J]. 应用科技, 2012, 39(5): 1-6.
JIANG S Y, ZHANG Y Q, ZHAO L H, et al.Analysis on Backward Ball Spinning of the Thin-Walled Tube with Longitudinal Inner Ribs Based on Various Wall Thickness Reductions[J]. Applied Science and Technology, 2012, 39(5): 1-6.
[9] ALVES L M, AFONSO R M, SILVA C M A, et al. Boss Forming of Annular Flanges in Thin-Walled Tubes[J]. Journal of Materials Processing Technology, 2017, 250: 182-189.
[10] QIAN D S, LI G C, DENG J D, et al.Effect of Die Structure on Extrusion Forming of Thin-Walled Component with I-Type Longitudinal Ribs[J]. The International Journal of Advanced Manufacturing Technology, 2020, 108(5): 1959-1971.
[11] ZENG X, FAN X G, LI H W, et al.Die Filling Mechanism in Flow Forming of Thin-Walled Tubular Parts with Cross Inner Ribs[J]. Journal of Manufacturing Processes, 2020, 58: 832-844.
[12] 马明娟, 詹梅, 杨合, 等. 异型薄壁壳体强力旋压三维有限元模型的建立[J]. 中国机械工程, 2006, 17(S1): 92-95.
MA M J, ZHAN M, YANG H, et al.3D FE Modeling of the Power Spinning of Complicated Thin-Walled Shell[J]. China Mechanical Engineering, 2006, 17(S1): 92-95.
[13] 闫静锴, 雒亚涛, 李冰, 等. 薄壁大尺寸铌铪合金零件强力旋压的数值模拟研究[J]. 锻压技术, 2023, 48(7): 64-70.
YAN J K, LUO Y T, LI B, et al.Numerical Simulation Study on Power Spinning for Nb-Hf Alloy Part with Thin Wall and Large Size[J]. Forging & Stamping Technology, 2023, 48(7): 64-70.
[14] 王雨, 束学道, 田端阳, 等. 工艺参数对薄壁锥形旋压件凸缘平直度的影响[J]. 机械科学与技术, 2017, 36(7): 1068-1072.
WANG Y, SHU X D, TIAN D Y, et al.Influence of Process Parameters on Flange Flatness of Conical Spun Parts with Thin Wall[J]. Mechanical Science and Technology for Aerospace Engineering, 2017, 36(7): 1068-1072.
[15] 王凤彪. 锥形件强力旋压壁厚的模拟预测及试验验证[D]. 重庆: 重庆大学, 2014: 43-44.
WANG F B.Research on the Wall Thickness by Simulation Prediction and Experimental Investigation During the Power Spinning of Cone Parts[D]. Chongqing: Chongqing University, 2014: 43-44.
[16] 周豪. 液压成形三通管壁厚均匀性研究与坯料反向设计[D]. 重庆: 重庆交通大学, 2024: 23-29.
ZHOU H.Research on Thickness Uniformity of T-shaped Tubes Hydroforming and Reverse Design of Tube Blanks[D]. Chongqing: Chongqing Jiaotong University, 2024: 23-29.
[17] 胡金, 温彤, 张梦, 等. 基于响应面法的筋肋板辊轧成形工艺参数优化[J]. 锻压技术, 2019, 44(8): 35-40.
HU J, WEN T, ZHANG M, et al.Optimization on Rolling Process Parameters for Rib Stiffened Plates Based on Respond Surface Method[J]. Forging & Stamping Technology, 2019, 44(8): 35-40.
[18] ZHANG Y, TAN J.Numerical Simulation and Vertical Motion Control of Rolls for Variable Gauge Rolling[J]. Journal of Iron and Steel Research, International, 2015, 22(8): 703-708.
[19] 付秀娟, 于歌, 赵严, 等. 过渡区位置变化对轧制差厚板拉深成形性能的影响[J]. 热加工工艺, 2020, 49(3): 96-100.
FU X J, YU G, ZHAO Y, et al.Effect of Transition Zone Position Change on Drawing Properties of TRB[J]. Hot Working Technology, 2020, 49(3): 96-100.
[20] 莫远东, 王雅芝, 黄舒琦, 等. 基于集成正交实验与CNN方法的微细电火花微孔加工精度[J]. 工程科学与技术, 2024, 56(4): 261-272.
MO Y D, WANG Y Z, HUANG S Q, et al.Micro-Electrical Discharge Machining of Micro-Holes Based on Integrated Orthogonal Experiments and CNN Methods[J]. Advanced Engineering Sciences, 2024, 56(4): 261-272.
[21] 张渝, 赵振兴. 面向壁厚均匀性的拉深成形TRB板形设计及神经网络预测模型[J]. 精密成形工程, 2023, 15(6): 37-45.
ZHANG Y, ZHAO Z X.Neural Network Prediction Model of Deep Drawing TRB Sheet for Wall Thickness Uniformity[J]. Journal of Netshape Forming Engineering, 2023, 15(6): 37-45.
[22] 刘玉琢, 曹立雄, 吴建国, 等. 基于自适应代理模型的加筋壳结构可靠性优化设计[J]. 机械强度, 2025, 47(2): 68-74.
LIU Y Z, CAO L X, WU J G, et al.Structural Reliability Optimization Design of Reinforced Shell Structure Based on Adaptive Surrogate Model[J]. Journal of Mechanical Strength, 2025, 47(2): 68-74.
[23] 张涛, 蒋荣超, 刘大维, 等. 基于Kriging模型的悬架控制臂轻量化多目标优化[J]. 机械设计, 2019, 36(S2): 28-32.
ZHANG T, JIANG R C, LIU D W, et al.Multi-Objective Optimization of Lightweight Suspension Control Arm Based on Kriging Model[J]. Journal of Machine Design, 2019, 36(S2): 28-32.
[24] 胡少武, 王涛, 黄旭东, 等. 基于预测模型和NSGA-II的激光除漆工艺参数优化[J/OL]. 激光与光电子学进展, 2022: 1-13. (2022-07-18). https://kns.cnki.net/KCMS/detail/detail.aspx?filename=JGDJ2022071306O&dbname=CJFD&dbcode=CJFQ.
HU S W, WANG T, HUANG X D, et al. Optimization of Laser Paint Removal Process Parameters Based on Prediction Model and NSGA-II[J/OL]. Laser & Optoelectronics Progress, 2022: 1-13. (2022-07-18). https://kns.cnki.net/KCMS/detail/detail.aspx?filename=JGDJ2022071306O&dbname=CJFD&dbcode=CJFQ.
[25] 宋晓雯, 杨晓珍, 杨玉好, 等. 尾灯安装加强件拉延工艺的动态NSGA-II多目标优化[J]. 锻压技术, 2022, 47(3): 72-78.
SONG X W, YANG X Z, YANG Y H, et al.Multi-Objective Optimization of Dynamic NSGA-II on Drawing Process for Taillight Mounting Reinforcement[J]. Forging & Stamping Technology, 2022, 47(3): 72-78.