目的 揭示3 350 mm级大直径铝合金筒段交叉网格筋填充率的影响因素,研究坯料在旋轮作用下的流动填充规律及主要影响因素,为未来火箭轻量化制造应用提供理论基础。方法 通过强力旋压成形方法成形2219铝合金网格筋筒体,分析减薄率、进给比、坯料壁厚对成形中筋条填充的影响规律。结果 随减薄率的增加,筋条填充高度不断增大,当减薄率达到60%时,筋条填充高度达到最大,但当减薄率高于50%时,筋条填充率出现下降现象。当进给比为0.6~0.8时,填充效果良好,当进给比过低时,会出现扩径现象,当进给比过高时,填充不均匀,会导致填充率下降。当坯料壁厚为15 mm时,填充效果良好,当壁厚过低时,在局部范围内可能出现撕裂缺陷,当壁厚过大时金属倾向于向前流动。结论 在铝合金筒段整体旋压中,减薄率和进给比对筋条填充影响较大,减薄率增大有助于筋条填充饱满,但当减薄率高于60%时,金属向旋压方向流动过大,导致反方向区域出现空隙从而影响整体填充率。当进给比过低时,会出现扩径现象,当进给比过高时,旋轮每转前进的距离更长,导致坯料变形不充分,筋条高度不均匀等现象均会影响交叉网格筋填充率。
Abstract
The work aims to reveal the influencing factors of the filling rate of 3 350 mm-level large-diameter aluminum alloy cylinder segments with cross-grid ribs, uncover the flow and filling patterns of billets and their main influencing factors under roller action, and provide a theoretical foundation for future lightweight rocket manufacturing applications. A 2219 aluminum alloy grid rib cylinder was formed using strong spinning, and the effects of the thinning rate, feed ratio, and billet wall thickness on rib filling during forming were analyzed. The study found that increasing the thinning rate enhanced filling height, with maximum rib filling achieved at a 60% thinning rate. However, the rib filling rate declined when the thinning rate exceeded 50%. A feed ratio between 0.6 and 0.8 ensured optimal filling, while excessively low ratios caused diameter expansion and excessively high ratios led to uneven filling, both reducing the filling rate. A billet wall thickness of 15 mm yielded good filling, whereas lower thicknesses may result in localized tearing defects, and thicker walls caused metal to flow forward excessively. In the overall spinning of aluminum alloy cylinder segments, the thinning rate and the feed ratio significantly affect rib filling. Increasing the thinning rate promotes rib filling but, when exceeding 60%, excessive metal flow toward the spinning direction creates gaps in the opposite region, thereby reducing the overall filling rate. Both insufficient diameter expansion at low feed ratios and incomplete billet deformation at high feed ratios due to increased per-rotation advancement lead to uneven rib heights and negatively affect the cross-grid rib filling rate.
关键词
网格筋筒体 /
强力旋压 /
筋条填充率 /
扩径量 /
表面缺陷
Key words
grid rib cylinder /
strong spinning /
rib filling rate /
expansion amount /
surface defect
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] 顾孟奇, 朱家才, 郭万林, 等. 可重复使用运载火箭结构疲劳耐久性与可靠性展望[J]. 航空学报, 2023, 44(23): 27-50.
GU M Q, ZHU J C, GUO W L, et al.Prospects for Fatigue Durability and Reliability of Reusable Launch Vehicle Structures[J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(23): 27-50.
[2] 马领航, 李波, 赵彦广, 等. 火箭贮箱焊接缺陷修复技术研究现状[J]. 电焊机, 2023, 53(3): 31-45.
MA L H, LI B, ZHAO Y G, et al.Research Status of Welding Defect Repair Technology for Rocket Fuel Tank[J]. Electric Welding Machine, 2023, 53(3): 31-45.
[3] 包为民. 可重复使用运载火箭技术发展综述[J]. 航空学报, 2023, 44(23): 629555.
BAO W M.A Review of Reusable Launch Vehicle Technology Development[J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(23): 629555.
[4] 李雨, 王建刚, 杨菊鹏, 等. 火箭贮箱结构材料应用及发展现状[J]. 宇航材料工艺, 2024, 54(2): 29-42.
LI Y, WANG J G, YANG J P, et al.Application and Development Status of Rocket Tank Structural Materials[J]. Aerospace Materials & Technology, 2024, 54(2): 29-42.
[5] 彭赫力, 孟佳杰, 杨学勤, 等. 带筋筒段旋压蠕变时效复合成形方法: CN202411022581.9[P].2024-10-22.
PENG H L, MENG J J, YANG X Q, et al. A Combined Spinning-creep Age Forming Method for Grid-reinforced Cylinder: CN202411022581.9[P].2024-07-29.
[6] 商琳琳. AZ80,ZK60铸态镁合金高温变形行为研究[D]. 沈阳: 沈阳理工大学, 2009: 3-12.
SHANG L L.Study on High Temperature Deformation Behavior of As-cast AZ80 and ZK60 Magnesium Alloys[D]. Shenyang: Shenyang Ligong University, 2009: 3-12.
[7] WANG F Q, YU Z Q, GAN T.Study on Microstructure Evolution Mechanism and Inhomogeneous Characteristic of 2219 Aluminum Alloy in Hot Flow Forming[J]. Materials Characterization, 2024, 215: 114156.
[8] HAN X H, HUA L, PENG L, et al.An Innovative Radial Envelope Forming Method for Manufacturing Thin-Walled Cylindrical Ring with Inner Web Ribs[J]. Journal of Materials Processing Technology, 2020, 286: 116836.
[9] 孙瑜, 郑祖杰, 圣冬冬, 等. 航天大型复杂结构件数控加工编程技术发展现状与趋势[J]. 工具技术, 2021, 55(6): 13-17.
SUN Y, ZHENG Z J, SHENG D D, et al.Development Status and Trend of NC Machining Programming Technology for Aerospace Large-Scale Complex Structural Parts[J]. Tool Engineering, 2021, 55(6): 13-17.
[10] 于忠奇, 王凤琪, 戴冬华, 等. 带筋薄壁筒体类构件流动旋压技术研究进展[J]. 塑性工程学报, 2021, 28(8): 1-10.
YU Z Q, WANG F Q, DAI D H, et al.A Review of Flow Spinning Technology of Stiffened Thin-Walled Cylinders[J]. Journal of Plasticity Engineering, 2021, 28(8): 1-10.
[11] GAO P F, YU C, FU M W, et al.Formability Enhancement in Hot Spinning of Titanium Alloy Thin-Walled Tube via Prediction and Control of Ductile Fracture[J]. Chinese Journal of Aeronautics, 2022, 35(2): 320-331.
[12] TEBAAY L M, HAHN M, TEKKAYA A E.Distortion and Dilution Behavior for Laser Metal Deposition onto Thin Sheet Metals[J]. International Journal of Precision Engineering and Manufacturing-Green Technology, 2020, 7(3): 625-634.
[13] LI L W, ZHOU D H, WEI C B, et al.Microstructure Evolution and Mechanical Properties at Ambient and Elevated Temperatures of In-Situ TiB2/2219Al Matrix Composites during Cold Rolling[J]. Metals and Materials International, 2024, 30(10): 2791-2807.
[14] GU B, HE J, LI S H, et al. Anisotropic Fracture Modeling of Sheet Metals: From In-Plane to Out-of-Plane[J]. International Journal of Solids and Structures, 2020, 182/183: 112-140.
[15] 朱正午, 赵亦希, 于忠奇, 等. 筒形件中不同结构筋条整体成形方法综述[J]. 塑性工程学报, 2024, 31(1): 83-98.
ZHU Z W, ZHAO Y X, YU Z Q, et al.Review of Integral Forming Methods of Different Structural Ribs of Cylinders[J]. Journal of Plasticity Engineering, 2024, 31(1): 83-98.
[16] 赵升吨, 赵承伟, 王君峰, 等. 现代旋压设备发展趋势的探讨[J]. 中国机械工程, 2012, 23(10): 1251-1255.
ZHAO S D, ZHAO C W, WANG J F, et al.Discussion about Development Trends of Modern Spinning Equipment[J]. China Mechanical Engineering, 2012, 23(10): 1251-1255.
[17] 王凤琪, 于忠奇, 孟烨晖, 等. 复杂内筋铝筒段旋压变形规律和再结晶组织演变数值仿真[J]. 航空学报, 2023, 44(9): 92-102.
WANG F Q, YU Z Q, MENG Y H, et al.Deformation Mechanism and Recrystallization Microstructure Evolution of Aluminum Stiffened Cylinder during Hot Flow Spinning Based on Numerical Simulation[J]. Acta Aeronautica et Astronautica Sinica, 2023, 44(9): 92-102.
[18] XU H Q, LI M Z, LI L L, et al.Power Spinning Study of Thin-Walled 5A06 Aluminum Alloy Cylinder with Longitudinal and Hoop Inner Ribs for Manufacturing Engineering[J]. Advanced Materials Research, 2012, 583: 301-305.
[19] BANERJEE A, NELSON K, ROSZAK J, et al.Sustainable Manufacturing of a High-Value Tubular Ti-6Al-4V Component Using Flow-Forming Process; Effect of Feed-Rate on Microstructure Evolution[J]. Materials Chemistry and Physics, 2025, 344: 131086.
[20] LYU W, ZHAN M, GAO P F, et al.Improvement of Rib-Grid Structure of Thin-Walled Tube with Helical Grid-Stiffened Ribs Based on the Multi-Mode Filling Behaviors in Flow Forming[J]. Journal of Materials Processing Technology, 2021, 296: 117167.
[21] YANG H L.Creep Age Forming Investigation on Aluminum Alloy 2219 and Related Studies[D]. London: Imperial College London, 2013.
[22] ZENG X, FAN X G, LI H W, et al.Flow Forming Process of Thin-Walled Tubular Parts with Cross Inner Ribs[J]. Procedia Manufacturing, 2018, 15: 1239-1246.
[23] LI Y Z, GU D D, SHI X Y, et al.Influence of Environmental Constraints and Carrier Gas Velocity on Powder Concentration and Temperature Distribution during Laser Inside Additive Manufacturing Process[J]. CIRP Journal of Manufacturing Science and Technology, 2021, 32: 70-80.
[24] RAJ S, BISWAS P.Experimental Investigation of the Effect of Induction Preheating on the Microstructure Evolution and Corrosion Behaviour of Dissimilar FSW (IN718 and SS316L) Joints[J]. Journal of Manufacturing Processes, 2023, 95: 143-159.
[25] ZHOU W B, CLEAVER C J, DUNANT C F, et al.Cost, Range Anxiety and Future Electricity Supply: A Review of how Today's Technology Trends may Influence the Future Uptake of BEVs[J]. Renewable and Sustainable Energy Reviews, 2023, 173: 113074.
[26] 姚喆赫, 洪锦源, 范伟鑫, 等. 异形波纹板激光弯曲成形面畸变抑制策略研究[J]. 中国激光, 2023, 50(20): 56-66.
YAO Z H, HONG J Y, FAN W X, et al.Research on Suppression Strategy of Plane Distortion in Laser Bending Forming of Specialty-Shaped Corrugated Sheet[J]. Chinese Journal of Lasers, 2023, 50(20): 56-66.
[27] 许斌, 郝予琛, 杨海洋, 等. 防空导弹结构轻量化技术的发展与展望[J]. 空天防御, 2024, 7(3): 1-13.
XU B, HAO Y C, YANG H Y, et al.Development and Prospect of Lightweight Technology for Anti-Aircraft Missile Structures[J]. Air & Space Defense, 2024, 7(3): 1-13.
[28] 吕伟, 龚熠莉, 任志朋. 2219铝合金带螺旋交叉内筋筒形件旋压充筋行为研究[J]. 精密成形工程, 2025, 17(12): 147-156.
LYU W, GONG Y L, REN Z P.Rib Filling Behavior in Spinning of 2219 Aluminum Alloy Tubes with Helical Grid-Stiffed Inner Ribs[J]. Journal of Netshape Forming Engineering, 2025, 17(12): 147-156.
[29] 栾谦聪, 董湘怀, 吴云剑. 径向锻造工艺参数对锻透性的影响[J]. 中国机械工程, 2014, 25(22): 3098-3103.
LUAN Q C, DONG X H, WU Y J.Effects of Process Parameters on FPE in Radial Forging Processes[J]. China Mechanical Engineering, 2014, 25(22): 3098-3103.
基金
国家重点研发计划（2021YFB3400900）
PDF(5991 KB)
渝公网安备 50010702501719号 渝ICP备15012534号-4
