目的 针对2195铝锂合金薄壁网格筋筒段旋压成形过程中存在的流动性不足、薄壁网格筋筒段筋条部位材料填充不充分、最终影响筒段综合性能的问题,分析旋压过程中关键工艺参数对2195铝锂合金薄壁网格筋筒段筋条填充的影响。方法 基于有限元模拟仿真的方法分析了旋压过程中的关键工艺参数,选取筒段典型筋条特征截面位置展开分析,以旋压成形后筋条的高度作为成形后网格筋筒段筋条填充饱满程度的指标,分析了旋压温度、进给比、旋轮径向错距量分配方式3种工艺参数对2195铝锂合金薄壁网格筋筒段筋条填充饱满程度的影响。结果 仿真结果表明,相对的旋压温度对网格筋筒段筋条填充饱满度影响并不大,但适当升温有利于降低材料弹性模量、强度和结构刚性,从而实现旋压后回弹的降低,提高材料贴模度,提高成形精度;随着旋压进给比的增加,网格筋筒段的筋条填充性先升后降,当旋压进给比为2~4 mm/r时,筋条填充性能较好;对于径向错距量,当采用平均分配方式时,有利于筋条填充。结论 当采用本文仿真分析获得的工艺参数时,旋压成形出具有较高尺寸精度、直径200 mm及550 mm的2195铝锂合金网格筋筒段缩比样件及全尺寸样件。
Abstract
The work aims to analyze the effect of key process parameters of spinning forming on the rib filling fullness of 2195 aluminum-lithium (Al-Li) alloy to solve the problem that it is difficult to achieve sufficient material filling in the ribs during the spinning forming of thin-walled cylinders with cross ribs of 2195 Al-Li alloy due to insufficient material flowability, which affects the overall performance of cylinders. Based on the finite element simulation method, key process parameters of spinning forming were analyzed from the characteristic cross-sectional positions of typical ribs in cylinders. Taking the rib height after spinning forming as the indicator of the filling fullness of ribs in cylinders of cross ribs after forming, the influences of three process parameters, namely spinning temperature, feed ratio, and the distribution method of radial offset of the spinning wheel, on the fullness of thin-walled cylinders with cross ribs of 2195 Al-Li alloy were analyzed. The results show that the spinning temperature had little influence on the ribs height. However, increasing the temperature was beneficial to reducing the elastic modulus, strength and structural rigidity of the material, decreasing the springback after spinning and improving the fittability and forming precision. With the increase of the spinning feed ratio, the rib filling fullness first increased and then decreased. When the spinning feed ratio was in the range of 2-4 mm/r, the rib filling fullness was better. It was beneficial for rib filling fullness to adopt the average distribution method for the stepped amount of the radial. Based on the process parameters obtained from the simulation analysis in this paper, scaled and full-scale samples of thin-walled cylinder with cross ribs of 2195 Al-Li alloy with diameters of 200 mm and 550 mm and high dimensional accuracy are formed.
关键词
2195铝锂合金 /
薄壁网格筋筒段 /
流动旋压 /
筋条填充饱满度 /
有限元仿真
Key words
2195 Al-Li alloy /
thin-walled cylinders with cross ribs /
flow spinning forming /
rib filling fullness /
finite element simulation
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基金
国防基础科研计划（JCKY2022203C049）
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