目的 为满足旋压件“多品种、小批量”的生产需求,提出一种可适应多种薄壁锥形件加工的可调芯模旋压成形方法。方法 基于离散组合思想设计由中心芯轴与环筒式可调单元组成的柔性芯模结构,以可调单元圆角半径、单元壁厚、旋轮间隙率、旋轮圆角半径和旋轮安装角为试验因素,构建正交试验研究结构参数对壁厚差、直线度、平均壁厚偏离率和最小减薄率的影响。建立Kriging近似模型,并采用AMGA-HJ组合优化算法实现多目标参数优化。通过有限元仿真对比分析传统旋压、无模旋压与可调芯模旋压的成形规律,验证可调芯模旋压工艺的成形优势。结果 采用可调芯模旋压工艺可实现多种薄壁锥形件的稳定成形,所得产品兼具传统旋压的支撑特性与无模旋压的柔性特性。使用多目标优化得到结构参数的最优解,成形件平均壁厚偏离率降低至2.823%,壁厚差与母线直线度显著改善,仿真预测误差小于5%。结论 所设计的可调芯模结构合理可行,有效提升了旋压工艺柔性,为多规格薄壁回转件成形提供了一种新型柔性制造技术方案。
Abstract
The work aims to propose an adjustable mandrel spinning forming method to meet the "multi-variety and small-batch" production demand of thin-walled conical parts. A flexible mandrel composed of a central mandrel and circumferential adjustable ring units was designed based on the discrete combination concept. With the adjustable unit fillet radius, unit wall thickness, roller gap ratio, roller fillet radius and roller mounting angle as experimental factors, an orthogonal experiment was constructed to investigate the effects of structural parameters on wall thickness difference, straightness, average wall thickness deviation, and minimum thinning rate. A Kriging surrogate model was established, and multi-objective optimization was performed with the AMGA-HJ algorithm. Finite element simulations were conducted to compare the forming laws of conventional mandrel spinning, dieless spinning, and adjustable mandrel spinning and verify the forming advantages of adjustable mandrel spinning. The adjustable mandrel spinning enabled stable forming of various thin-walled conical parts, combining the supporting performance of conventional spinning and the flexibility of dieless spinning. Multi-objective optimization was adopted to obtain the optimal solution of structural parameters. The average wall thickness deviation rate of formed parts was reduced to 2.823%, the wall thickness difference and generatrix straightness were greatly improved, and the simulation prediction error was less than 5%. The designed adjustable mandrel features a reasonable and feasible structure, which effectively improves the flexibility of the spinning process and provides a novel flexible manufacturing technical scheme for forming thin-walled rotary parts of multiple specifications.
关键词
可调芯模旋压 /
壁厚均匀性 /
薄壁锥形件 /
正交设计 /
多目标优化
Key words
adjustable mandrel spinning /
wall thickness uniformity /
thin-walled conical parts /
orthogonal design /
multi-objective optimization
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基金
重庆市自然科学基金面上项目（CSTB2022NSCQ-MSX1444）
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