铝合金大型薄壁异型曲面封头旋压成形研究进展

Large-sized thin-walled and special-curved surface heads are the urgent needs of aerospace and aviation industry for its high-performance and lightweight. Spinning-quenching is one effective integral forming process to manufacture these components. However, the spinning of large-sized thin-walled and special-curved surface head is one of the complicated local loading/unloading processes under the action of multi-parameters and their coupled effects. In this process, the heads are very prone to produce forming defects, such as local damage rupture, flange wrinkling, local bulge, and unfitting. Additionally, the quenching treatment after spinning will lead to heavy quenching distortion and residual stress, thus seriously deteriorate the material performance. In this work, a finite element model for the whole process of spinning-quenching are established. Based on the model, the distribution and evolution of stress and strain field of the large-sized thin-walled and special-curved surface heads during spinning process is analyzed. In order to obtain the effect laws of process parameters on flange circumferential compressive stress, the mechanism of flange wrinkling is investigated, and a method of controlling the flange wrinkling is proposed. The effect laws of the thickness variation of slabs on deformation quality are investigated. The quenching residual stress and distortion of the large sized thin-walled and special-curved surface heads are also studied.