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大尺寸超薄不锈钢复杂构件的精密成形是支撑航空航天飞行器轻量化发展的关键技术之一，但其成形过程中易出现破裂与起皱等失稳问题，且工艺窗口狭窄。以厚度为0.2 mm、厚径比仅为0.33‰的半球形构件为对象，开展主动式充液-覆板成形工艺研究，结合有限元仿真与实验系统分析了目标板在不同覆板结构下的成形性能与缺陷演化规律。结果表明：单层结构中，仅调整压边压强难以同时抑制破裂与起皱；下侧覆板通过摩擦与包覆协同机制显著提升目标板的应变均匀性与成形极限，最大等效应变由0.31降至0.14;双侧覆板进一步消除起皱，但存在破裂风险略升的问题。实验验证了仿真预测的有效性：双侧覆板工艺成功获得无缺陷零件，单侧覆板试样也有效贴模，仅在凹模圆角存在少量死皱。
Abstract：Accurate forming of large-scale ultra-thin stainless steel complex components is one of the essential techniques to support lightweight development of aerospace aircarft, but crack and wrinkling problems are easy to occur during its forming process, and the process window is narrow. This study investigates a hemispherical part with thickness of 0.2 mm and thickness-to-diameter ratio of only 0.33‰, employing an active cladding hydroforming process. Finite element simulations and experiments were conducted to systematically analyze the forming performance and defect evolution of the target sheet under different cladding configurations. The results show that in the single-layer structure, adjusting the blank holder pressure alone fails to suppress both fracture and wrinkling simultaneously; the lower cladding sheet significantly improves strain uniformity and forming limit via friction-wrapping coordination mechanism, reducing the maximum equivalent strain from 0.31 to 0.14;the double-cladding sheet further eliminates wrinkling but slightly increases the fracture risk. The experiment confirms the effectiveness of simulation predictions: defect-free components are successfully formed using the double-cladding process, while the single-cladding sample also achieves full die conformance with minor dead wrinkles at the die shoulder.
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基本信息:
中图分类号:V261;TG306
引用信息:
[1]李浩海,矫志辉,李建伟,等.大尺寸超薄板充液-覆板成形叠层参数影响仿真与实验研究[J].塑性工程学报,2026,33(08):52-60.
基金信息:
北京市自然基金资助项目(L2605010); 航空科学基金资助项目(20230036051001)
2026-08-21
2026-08-21
2026-08-21