CN114147124A - Continuous forming die for large-cavity-diameter-ratio compensator for spaceflight and forming control method thereof - Google Patents

Continuous forming die for large-cavity-diameter-ratio compensator for spaceflight and forming control method thereof Download PDF

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Publication number
CN114147124A
CN114147124A CN202111429832.1A CN202111429832A CN114147124A CN 114147124 A CN114147124 A CN 114147124A CN 202111429832 A CN202111429832 A CN 202111429832A CN 114147124 A CN114147124 A CN 114147124A
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forming
die
fixed
movable
module
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CN114147124B (en
Inventor
胡德友
王贺
李继光
张杰刚
陶现宾
张艳丰
彭江涛
王东
初冠南
孙磊
梁立冬
赵培钧
孟旭
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Tianjin Aerospace Changzheng Rocket Manufacturing Co ltd
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Tianjin Aerospace Changzheng Rocket Manufacturing Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/08—Dies with different parts for several steps in a process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
    • B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/92—Making other particular articles other parts for aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/40—Weight reduction

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  • Mechanical Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

The invention provides a continuous forming die of a large cavity-diameter ratio compensator for aerospace and a forming control method thereof. The invention relates to a continuous forming die for a large cavity-diameter ratio compensator for aerospace and a forming control method thereof, and mainly aims to combine the characteristics of the negative angle structure section of the large cavity-diameter ratio omega-shaped compensator for aerospace and the characteristics of a low-elongation material, establish a continuous forming die design which takes single-wave differential shape positioning and back-wave single-cavity forming as purposes based on forming profiles and hydraulic test requirements, form a flexible medium auxiliary corrugated continuous forming process method, match a process parameter database, ensure the forming precision of the large cavity-diameter ratio omega-shaped compensator for aerospace, solve the problems of poor forming precision and difficult negative angle mold taking, realize accurate continuous operation and improve the precision and reliability of products.

Description

Continuous forming die for large-cavity-diameter-ratio compensator for spaceflight and forming control method thereof
Technical Field
The invention belongs to the technical field of aerospace compensator molds, and particularly relates to a continuous forming mold for an aerospace compensator with a large cavity-diameter ratio and a forming control method thereof.
Background
The compensator is used as an important structural member in the storage tank of the carrier rocket and is matched with a tunnel pipe or a conveying pipe to penetrate through the whole storage tank, so that the effect of protecting the conveying pipe to convey the oxidant is achieved. In order to ensure effective impact bearing of internal and external pressures of fuel and maintain certain compression and extension elasticity, a compensator is usually designed to be a deep cavity type closed structure, presents omega shape and has tangent and variable cross sections, is a rotary thin-wall shell with a corrugated bus, is made of 5A03 non-heat-treatable strengthened aluminum alloy, has remarkable processing and hardening effects, has the thickness of 1.5mm, and has the internal diameter size coverage range of phi 330 mm-phi 740mm, wherein the cavity depth is up to 40.87mm, but the cavity opening distance is smaller and only 9.35mm, and the cavity diameter ratio is up to 4.37, specifically shown in figures 4-5, the design requirement is that the thinning cannot exceed 15%, the profile precision deviation is not more than 0.5mm, the forming difficulty is larger, the stress concentration at the round corner is obvious, the thinning is serious, and the fracture is easily caused.
According to the structure of the compensator, the strength and the elongation of materials (aluminum alloy and stainless steel), the existing large-cavity-diameter-ratio compensator is mainly formed by the modes of split combined welding, rolling forming, hydraulic bulging and the like.
(1) Split combination welding
As shown in fig. 6-7, since the elongation of 5a03 aluminum alloy is low (about 20%), the integral forming is easy to be thinned and broken, and the existing compensator is generally drawn by using a single diaphragm, and then tens of single diaphragms are combined and welded to ensure the integral structure.
(2) Roll forming
Roll forming is typically used to machine annular stainless steel metal bellows, as shown in fig. 8. The forming principle is shown in fig. 3, during roll forming, the tube blank moves along with the driving wheel under the action of friction force, and the tube blank generates plastic deformation through the radial movement of the driven wheel so as to form corrugations. The rolling forming method can be used for manufacturing large-diameter corrugated pipes, in the rolling process, in order to enable thin-wall and large-diameter pipe blanks to stably rotate along the axes of the pipe blanks, the pipe blanks are required to be installed on an auxiliary clamp, and a working wheel is driven by a high-power motor and can automatically feed back according to the load condition to maintain a constant state. At present, the large-diameter pipe is formed by a multi-purpose rolling welding process, and is not suitable for rolling forming due to poor weld performance. The production efficiency of the roll forming corrugated pipe is low, the roller continuously rolls the surface of the pipe blank, so that a hardened layer is formed on the surface to generate large residual stress, meanwhile, the surface generates serious mechanical damage, and the wall thickness reduction amount of the wave trough and the wave crest is uneven.
(3) Hydroforming
As shown in fig. 9-13, hydroforming is a die having separate passages for providing a forming medium under pressure, and the die is composed of upper and lower multi-piece dies and left and right extrusion punches. The forming process of the corrugated pipe comprises the following steps:
a) placing a tube blank: placing the tube blank into a lower half die;
b) closing the mold and filling the liquid forming medium: closing the upper half die and the lower half die, enabling the extrusion punches at the two ends to penetrate into the two ports of the blank pipe to form a closed cavity, and filling the inner cavity with a liquid medium through a special pipeline;
c) primary forming: pressurizing the liquid forming medium, and bulging the blank to finish primary forming;
d) final forming: keeping the pressure, enabling the extrusion punches at the two ends to start to move towards the middle, driving the die and the blank pipe to move at the same time, and finally reaching the position shown in the figure to finish forming;
e) and (3) finishing forming: and finally releasing the pressure, discharging the liquid, separating the upper half die from the lower half die, and withdrawing the extrusion punch.
The three forming processes have the advantages and the disadvantages, wherein the split combined welding has stronger applicability, but has higher requirement on welding, and the forming precision and the reliability of the product are poorer; the rolling forming can realize the integral forming of the material with better plasticity, the contact of the pipe material and the upper and lower dies belongs to rigid die hard contact, the surface of the product is very easy to scratch or even break, and the forming consistency is poor; the hydraulic forming belongs to flexible contact of forming media, pipe materials and dies, the surface quality of a product is good, but the requirements on internal pressure and die positioning accuracy are high, the whole body is formed in one step, the controllability is low, thinning difference of all sections is easily caused, and failure risk points exist.
Disclosure of Invention
In view of this, the present invention provides a continuous forming mold for a large cavity-diameter ratio compensator for aerospace use, so as to solve the disadvantages of the existing forming apparatus.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a continuous forming die for a large cavity-diameter ratio compensator for aerospace comprises a movable die set and a fixed die set, wherein the movable die set and the fixed die set are both of annular body structures with adjustable diameters, the movable die set is used for controlling the thinning rate and the profile precision of a workpiece, the fixed die set is arranged in the middle of the movable die set, the fixed die set is used for positioning the waveform of the workpiece, and the movable die set and the fixed die set are both installed in external forming equipment;
the movable die set comprises a plurality of movable die units, each movable die unit is of a fan-shaped structure, the plurality of movable die units form an annular body structure with adjustable diameter, and the fixed die set is located in the center of the annular body structure.
Further, the movable die unit comprises a movable die body and a movable core die, a fixed module is arranged on one side of the movable die body, the bottom of the movable die body is fixedly connected to the movable core die, the cross section of the movable core die is of an L-shaped structure, a first sealed air inlet is formed in the top of the movable core die, and the first sealed air inlet is of an L-shaped structure.
Furthermore, the movable die body is of a special-shaped structure, and an inlet and outlet hole is reserved between the movable die body and the movable core die and used for placing a workpiece.
Furthermore, the movable die unit is further provided with a first sealing ring, and the first sealing ring is located in the first sealing air inlet.
Further, fixed module includes fixed mould body and fixed mandrel, fixed mould body is the ring body structure, fixed mould body bottom is equipped with fixed mandrel, and fixed mould body is located fixed mandrel top one side, and fixed mandrel top opposite side is equipped with the removal mandrel, and fixed mandrel top is close to removal mandrel one side and has seted up the air inlet of taking shape, and fixed mandrel top is close to fixed mandrel one side and has seted up No. two sealed air inlets.
Further, the bottom of the fixed die body is provided with a chamfer.
Furthermore, the bottom of the fixed mould body is provided with a groove, a straight edge section and a wave-shaped section are arranged in the groove, and the gap distance between the straight edge section and the wave-shaped section is not less than 1 mm.
Further, fixed module still is equipped with No. two sealing rings, No. two sealing rings are located No. two sealed inlets.
Compared with the prior art, the aerospace large-cavity-diameter-ratio compensator continuous forming die has the following advantages:
(1) the invention relates to a continuous forming die for a large cavity-diameter ratio compensator for aerospace, which mainly aims to establish a continuous forming die design for realizing the purposes of single-wave differential positioning and back-wave single-cavity forming based on a forming profile and hydraulic test requirements by combining the negative angle structure section characteristics and the low elongation material characteristics of an omega-shaped compensator for the large cavity-diameter ratio for aerospace, ensure the forming precision of the omega-shaped compensator for the large cavity-diameter ratio for aerospace, solve the problems of poor forming precision and difficult negative angle mold taking, realize accurate continuous operation and improve the precision and reliability of products.
The invention also aims to provide a forming control method of the aerospace compensator with the large cavity-diameter ratio, so as to solve the defects in the existing forming control method.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a forming control method of a large cavity-diameter ratio compensator for spaceflight comprises the following steps:
s1, setting forming process parameters;
s2, continuously forming the workpiece through the aerospace large cavity-diameter ratio compensator continuous forming die;
the forming process parameters in step S1 include internal pressure, amount of material supply, and load path, respectively.
Further, the continuous forming operation in step S2 includes the steps of:
s21, loading the workpiece in the mobile module;
s22, closing the movable module and the fixed module, pressurizing and maintaining the pressure of the workpiece, and forming the compensator corrugation;
s23, moving the moving module to open the die for the workpiece;
and S24, moving the fixed module, and performing longitudinal die sinking on the workpiece to obtain the formed workpiece.
Compared with the prior art, the forming control method of the aerospace compensator with the large cavity-diameter ratio has the following advantages:
(1) the invention relates to a forming control method of an aerospace large-cavity-diameter-ratio compensator, and mainly aims to explore a precise continuous forming mold design and a forming process control method of the aerospace large-cavity-diameter-ratio omega-shaped compensator by combining the negative angle structure section characteristics and the low-elongation material characteristics of the aerospace large-cavity-diameter-ratio omega-shaped compensator based on forming molded surfaces and hydraulic test requirements, match a process parameter database, ensure the forming precision of the aerospace large-cavity-diameter-ratio omega-shaped compensator, fully consider the material plasticity and the product stability, avoid excessive breakage due to thinning, formulate a continuous forming mold based on single-wave differential positioning and back-wave single-cavity forming as a process method, and form a flexible medium auxiliary precision continuous forming process method.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a cross-sectional view of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention;
FIG. 2 is a sectional view of a moving module of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention;
FIG. 3 is a sectional view of a fixed module of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention;
FIG. 4 is a schematic structural diagram of a continuous forming mold of a large cavity-diameter ratio compensator for aerospace and a forming control method thereof, and a carrier rocket compensator according to an embodiment of the invention;
FIG. 5 is an enlarged view of a continuous forming mold of a large cavity-diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention, wherein the structure of a carrier rocket compensator is enlarged;
FIG. 6 is a schematic structural diagram of a single diaphragm of a launch vehicle compensator of the continuous forming mold for the large cavity-diameter ratio compensator for aerospace and the forming control method thereof according to the embodiment of the invention;
FIG. 7 is a schematic view of a combined welding structure of a large cavity-diameter ratio compensator continuous forming mold for aerospace and a forming control method thereof according to an embodiment of the invention, and a carrier rocket compensator;
FIG. 8 is a schematic diagram of a roll forming process of a aerospace large cavity-diameter ratio compensator continuous forming mold and a forming control method thereof according to an embodiment of the invention;
FIG. 9 is a schematic view of a blank pipe placed in hydraulic forming of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention;
FIG. 10 is a schematic diagram of a mold closing and filling forming medium in hydraulic forming of a continuous forming mold for a large cavity-diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention;
FIG. 11 is a schematic view of the continuous forming mold of the aerospace compensator with a large cavity-diameter ratio and the forming control method thereof according to the embodiment of the invention during the hydraulic forming;
FIG. 12 is a schematic diagram of the final forming in the hydroforming process of the aerospace large cavity diameter ratio compensator continuous forming mold and the forming control method thereof according to the embodiment of the invention;
FIG. 13 is a schematic view of the continuous forming die of the aerospace large cavity-diameter ratio compensator and the forming control method thereof according to the embodiment of the invention, which are completed in the hydraulic forming;
FIG. 14 is a partial cross-sectional view of a aerospace large cavity diameter ratio compensator continuous forming mold and a forming control method thereof before forming according to an embodiment of the invention;
FIG. 15 is a partial cross-sectional view of a aerospace large cavity diameter ratio compensator continuous forming mold and a forming control method thereof after forming according to an embodiment of the invention;
FIG. 16 is a circumferential cross-sectional view of a aerospace large cavity-diameter ratio compensator continuous forming mold and a forming control method thereof according to an embodiment of the invention;
FIG. 17 is a partial cross-sectional view of an initial position of a aerospace large cavity diameter ratio compensator continuous forming mold and a forming control method thereof according to an embodiment of the invention;
fig. 18 is a partial sectional view showing the advancing of the moving core mold of the continuous forming mold for the aerospace large cavity diameter ratio compensator and the forming control method thereof according to the embodiment of the present invention;
FIG. 19 is a partial cross sectional view of a fixed mold clamping + fixed mold sealing of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention;
fig. 20 is a partial cross-sectional view of a moving mold clamping + moving mold sealing of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the present invention;
FIG. 21 is a partial cross-sectional view of a moving mold advancing + forming air intake of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the invention;
FIG. 22 is a partial cross-sectional view of the forming exhaust of the aerospace large cavity diameter ratio compensator continuous forming mold and the forming control method thereof according to the embodiment of the invention;
FIG. 23 is a partial cross-sectional view of a moving mold venting + moving mold retracting of a continuous forming mold for a large cavity diameter ratio compensator for aerospace and a forming control method thereof according to an embodiment of the present invention;
FIG. 24 is a partial cross sectional view of the aerospace large cavity diameter ratio compensator continuous forming mold and the forming control method thereof, wherein the mold is moved upwards and the air inlet seal + the fixed mold are moved upwards according to the embodiment of the invention;
FIG. 25 is a partial cross-sectional view of a progressive forming die of a large cavity diameter ratio compensator for aerospace and a forming control method thereof, wherein the progressive moving die and the downward moving fixed die are sealed according to an embodiment of the invention;
fig. 26 is a partial cross-sectional view illustrating the progressive movement of the mold in the continuous forming mold for the aerospace large cavity diameter ratio compensator and the forming control method thereof according to the embodiment of the invention.
Description of reference numerals:
1. a moving module; 11. a moving die unit; 111. moving the mold body; 112. moving the core mold; 113. sealing the air inlet; 114. an inlet and outlet hole; 115. a first sealing ring; 2. fixing the module; 21. fixing the mold body; 211. chamfering; 212. a groove; 22. fixing a core mold; 221. a shaped air inlet; 222. sealing the air inlet; 23. a first sealing ring; 3. a workpiece; 4. a circular closed hydraulic thrust device; 5. sealing the chamber; 6. a forming chamber.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art through specific situations.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
As shown in fig. 1 to 26, the aerospace large cavity-diameter ratio compensator continuous forming die comprises a moving module 1 and a fixed module 2, wherein the moving module 1 and the fixed module 2 are both in a ring body structure with adjustable diameters, the moving module 1 is used for controlling the thinning rate and the profile accuracy of a workpiece 3, namely a thin-walled tube, the fixed module 2 is arranged in the middle of the moving module 1, the fixed module 2 is used for positioning the waveform of the workpiece 3, and the moving module 1 and the fixed module 2 are both installed in external forming equipment;
the movable die set 1 comprises a plurality of movable die units 11, each movable die unit 11 is of a fan-shaped structure, the plurality of movable die units 11 form an annular body structure with adjustable diameter, and the fixed die set 2 is located in the center of the annular body structure. During the in-service use, remove the module 1 and fix the below in the former, fixed module 2 is fixed to the former top in, and the annular closed hydraulic thrust device 4 of a former of equal fixed connection of the outside cambered surface section of every moving die unit 11 realizes that the annular mould is closed. Thereby exert axial thrust through horizontal pressure (the power supply can be current transverse press) to the removal module after the closure and drive removal mould unit 11 back-and-forth movement on the horizontal direction to adjust the ring body structure diameter size that a plurality of removal mould units 11 are constituteed, fixed module 2 top is equipped with the cylinder assembly of former, thereby a cylinder assembly drives fixed module 2 and reciprocates in the vertical direction.
The invention gives full consideration to the plasticity of materials and the stability of products, avoids breaking due to too large thinning, makes a continuous forming die based on a process method of single-wave differential positioning and back-wave single-cavity forming, forms a flexible medium auxiliary precision continuous forming process method, and has the following process flows of the accurate continuous forming and control method of the large-cavity-diameter-ratio omega-shaped compensator: spinning preparation of a thin-walled tube → annealing → continuous forming of flexible medium assisted corrugation → detection → hydraulic airtightness → delivery.
The movable die unit 11 comprises a movable die body 111 and a movable core die 112, the movable die body 111 is of a special-shaped structure, an inlet and outlet hole 114 is reserved between the movable die body 111 and the movable core die 112, the inlet and outlet hole 114 is used for placing a workpiece 3, a fixed die set 2 is arranged on one side of the movable die body 111, the bottom of the movable die body 111 is fixedly connected to the movable core die 112, the cross section of the movable core die 112 is of an L-shaped structure, a first sealed air inlet 113 is further formed in the top of the movable core die 112, and the first sealed air inlet 113 is of an L-shaped structure. The moving die unit 11 is further provided with a first sealing ring 115, and the first sealing ring 115 is located in the first sealing air inlet 113. During specific implementation, the movable module 1 can control the distance to realize thinning rate and profile precision control by left and right movement, so that a single wave is precisely formed, and continuous operation of precise forming is met.
Fixed module 2 includes fixed mould body 21 and fixed mandrel 22, fixed mould body 21 is the ring body structure, fixed mould body 21 bottom is equipped with fixed mandrel 22, and fixed mould body 21 is located fixed mandrel 22 top one side, and fixed mandrel 22 top opposite side is equipped with removal mandrel 112, and fixed mandrel 22 top is close to removal mandrel 112 one side and has seted up shaping air inlet 221, and fixed mandrel 22 top is close to fixed mandrel 22 one side and has seted up No. two sealed air inlets 222, fixed module 2 still is equipped with No. two sealing washer 23, No. two sealing washer 23 are located No. two sealed air inlets 222. The first sealing ring 115 and the second sealing ring 23 do not have relative displacement sliding with the pipe wall of the formed workpiece, the sealing is reliable, and the service life of the sealing rings is long. The floating seal ensures the forming distance, so as to ensure the shape precision, and can avoid the problems that the traditional fixed inner seal can not be accurately controlled and the like.
The bottom of the fixed die body 21 is provided with a chamfer 211, and in this embodiment, the radius of the chamfer 221 is 5 mm.
The bottom of the fixed die body 21 is provided with a groove 212, a straight edge section and a waveform section are arranged in the groove 212, and the gap distance between the straight edge section and the waveform section is not less than 1 mm. The straight edge section and the wave-shaped section are arranged in the groove 212, so that the straight edge section and the wave-shaped section are convenient to draw out from the deep cavity after forming.
The forming control method of the aerospace large-cavity-diameter-ratio compensator comprises the following steps of:
s1, setting forming process parameters;
and S2, carrying out continuous forming operation on the workpiece 3 through the aerospace large cavity diameter ratio compensator continuous forming die. The invention mainly aims to combine the negative angle structure section characteristics and the low elongation material characteristics of the aerospace large cavity diameter ratio omega-shaped compensator, explore an accurate continuous forming mold design and a forming process control method of the aerospace large cavity diameter ratio omega-shaped compensator based on a forming molded surface and hydraulic test requirements, match a process parameter database, ensure the forming accuracy of the aerospace large cavity diameter ratio omega-shaped compensator, fully consider the material plasticity and the product stability, avoid excessive fracture due to thinning, formulate a continuous forming mold based on single wave differential shape positioning and back wave single cavity forming as a process method, and form a flexible medium assisted accurate continuous forming process method.
The forming process parameters in step S1 include internal pressure, amount of material supply, and load path, respectively.
The continuous forming operation in step S2 includes the steps of:
s21, feeding the workpiece 3 in the movable module 1, setting a gap between the movable module 1 and the fixed module 2 and fixing the first sealing ring 115 during specific implementation;
s22, closing the movable module 1 and the fixed module 2, starting external forming equipment to pressurize and pressure-maintain the workpiece 3, and forming the compensator corrugation; in this embodiment, the telescopic link extension of the cylinder subassembly of a staff control outside former, will fix module 2 and move down to make fixed mould body 21 card in the ring structure that a plurality of fixed mould bodies 21 are constituteed.
S23, carry out the inner chamber pressure release to work piece 3, remove and remove module 1, carry out the die sinking to work piece 3, in this embodiment, the staff controls the telescopic link shrink of the closed hydraulic thrust device 4 of hoop of outside former, will remove module 1 to keeping away from fixed module 2 direction and remove to make and remove module 1 and fixed module 2 separately.
S24, moving the fixed module 2, performing longitudinal mold opening on the workpiece 3 to obtain a formed workpiece, in this embodiment, implementing a transverse forward moving positioning forming wave according to a wave interval, then transversely backward moving by a wave interval, placing the wave interval at the initial forming position, and repeating the operations for multiple times to obtain the formed workpiece 3.
Example 1
1. Design of precise continuous forming die of large-cavity-diameter-ratio omega-shaped compensator
(1) In order to meet the requirement of continuous and accurate forming of the compensator, the overall structure is designed into a fixed module (green area) and a movable module (red area);
(2) the left molded surface of the fixed mold is designed into a theoretical curve of the outer surface of the compensator to ensure that the profile curve of the compensator is matched and formed with the movable mold;
(3) in order to facilitate the drawing out of the deep cavity after the forming, the right molded surface of the fixed mold is designed into a U-shaped section design, the root chamfer is R5mm, the smooth transition is realized between the root chamfer and the trough position of the compensator, the gap between the U-shaped section structure and the forming wave is kept to be 1-2mm, the fixed mold is prevented from impacting the surface of a product in the upper and lower mold closing process to cause surface quality damage, the up and down movement is realized by fully utilizing the elasticity and the plasticity of the material, the positioning waveform is realized, the straightness of the product is ensured, and the like, and the continuous forming operation is realized;
(4) the movable die is transversely driven by a hydraulic machine to realize left-right movement distance control, so that the reduction rate and the profile precision control are ensured, single waves are precisely formed, and the continuous operation of precise forming is met;
(5) the core mold adopts low-pressure follow-up sealing, the sealing structure can synchronously float along with the pressure head, the sealing ring does not have relative displacement sliding with the pipe wall of the formed workpiece, the sealing is reliable, and the service life of the sealing ring is long. The floating seal ensures the distance and displacement before and after forming, thereby ensuring the shape precision and avoiding the problems that the traditional fixed inner seal cannot be accurately controlled and the like;
(6) by adopting the design of the large-inner-diameter core mold, the projection area of the workpiece on the horizontal plane (namely the area of the sealing cavity 5) is reduced, the forming mold closing force is obviously reduced, and the large-tonnage investment of equipment is avoided.
(7) The annular mould is manufactured by 3 split pieces, the single piece mould realizes the closing action of the mould through the annular closing hydraulic thrust device 4, the joint and the embedding part adopt smooth transition, the sharp corner design is avoided, and the mould opening positioning and the cost reduction of the compensator can be quickly realized;
2. control method for accurate continuous forming process of large-cavity-diameter-ratio omega-shaped compensator
(8) Forming process parameters are as follows:
internal pressure: and (3) rapidly calculating the internal pressure of the engineering application according to the initial yield force and the cracking pressure, namely:
Figure BDA0003379843770000131
in the formula: pInner partForming internal pressure (MPa); t is the pipe wall thickness (mm); d is the diameter of the thin-walled tube; δ s is the material yield strength; δ b is the material tensile strength.
② supplementing material amount: according to the principle of unchanged volume, assuming that the thickness of the thin-walled tube is unchanged before and after forming, calculating theoretical expansion according to a neutral layer, in the actual forming process, the thickness is influenced by friction, loading and thinning, the actual control interval is smaller than the theoretical expansion, and the interval value is about 90% of the theoretical expansion by referring to a material stress-strain curve and the proportion degree of a deep cavity;
loading path: aiming at the omega-shaped compensator structure with the large cavity diameter ratio, a linear loading and constant pressure loading path is adopted, and the matching internal pressure is matched with the distance control, so that the corrugation forming quality is ensured.
(9) Continuous forming process
Firstly, feeding the thin-walled pipe, setting a control gap value, then carrying out low-pressure air inlet sealing by a first sealing ring 115, and fixing the pipe;
closing the movable module 1 and the fixed module 2, synchronously pressurizing and maintaining the pressure in the pipe, and forming the compensator corrugation;
releasing the pressure in the inner cavity, opening the die of the movable die set 1 and returning to the initial position;
fourthly, the fixed module 2 opens the mould along the longitudinal direction and realizes the transverse advancing movement positioning wave forming according to a wave interval;
the fixed module 2 transversely retreats by a wave interval and is arranged at the initial forming position;
sixthly, repeating the action.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.

Claims (10)

1. Continuous forming die of big chamber footpath ratio compensator for space flight, its characterized in that: the device comprises a movable module (1) and a fixed module (2), wherein the movable module (1) and the fixed module (2) are both in ring body structures with adjustable diameters, the movable module (1) is used for controlling the thinning rate and the profile precision of a workpiece (3), the fixed module (2) is arranged in the middle of the movable module (1), the fixed module (2) is used for positioning the waveform of the workpiece (3), and the movable module (1) and the fixed module (2) are both installed in external forming equipment;
the movable die set (1) comprises a plurality of movable die units (11), each movable die unit (11) is of a fan-shaped structure, the plurality of movable die units (11) form an annular body structure with adjustable diameter, and the fixed die set (2) is located in the center of the annular body structure.
2. The aerospace large cavity diameter ratio compensator continuous forming die as claimed in claim 1, wherein: the movable die unit (11) comprises a movable die body (111) and a movable core die (112), one side of the movable die body (111) is provided with a fixed die set (2), the bottom of the movable die body (111) is fixedly connected to the movable core die (112), the cross section of the movable core die (112) is of an L-shaped structure, the top of the movable core die (112) is provided with a first sealed air inlet (113), and the first sealed air inlet (113) is of an L-shaped structure.
3. The aerospace large cavity diameter ratio compensator continuous forming die as claimed in claim 2, wherein: the movable die body (111) is of a special-shaped structure, an access hole (14) is reserved between the movable die body (111) and the movable core die (112), and the access hole (114) is used for placing a workpiece (3).
4. The aerospace large cavity diameter ratio compensator continuous forming die as claimed in claim 2, wherein: the movable die unit (11) is further provided with a first sealing ring (115), and the first sealing ring (115) is located in the first sealing air inlet (113).
5. The aerospace large cavity diameter ratio compensator continuous forming die as claimed in claim 2, wherein: fixed module (2) are including fixed mould body (21) and fixed mandrel (22), fixed mould body (21) are the ring body structure, fixed mould body (21) bottom is equipped with fixed mandrel (22), and fixed mould body (21) are located fixed mandrel (22) top one side, and fixed mandrel (22) top opposite side is equipped with removes mandrel (112), and fixed mandrel (22) top is close to and has seted up shaping air inlet (221) on one side of removing mandrel (112), and fixed mandrel (22) top is close to fixed mandrel (22) one side and has seted up No. two sealed air inlets (222).
6. The aerospace large cavity diameter ratio compensator continuous forming die as claimed in claim 5, wherein: and a chamfer (211) is arranged at the bottom of the fixed die body (21).
7. The aerospace large cavity diameter ratio compensator continuous forming die as claimed in claim 5, wherein: the bottom of the fixed die body (21) is also provided with a groove (212), a straight edge section and a wave-shaped section are arranged in the groove (212), and the gap distance between the straight edge section and the wave-shaped section is not less than 1 mm.
8. The aerospace large cavity diameter ratio compensator continuous forming die as claimed in claim 5, wherein: fixed module (2) still are equipped with No. two sealing washer (23), No. two sealing washer (23) are located No. two sealed air inlets (222).
9. The forming control method of the large cavity-diameter ratio compensator for spaceflight is characterized by comprising the following steps of: the method comprises the following steps:
s1, setting forming process parameters;
s2, continuously forming the workpiece (3) by the aerospace large cavity-diameter ratio compensator continuous forming die;
the forming process parameters in step S1 include internal pressure, amount of material supply, and load path, respectively.
10. The aerospace large cavity diameter ratio compensator forming control method according to claim 9, wherein: the continuous forming operation in step S2 includes the steps of:
s21, feeding the workpiece (3) in the moving module (1);
s22, closing the movable module (1) and the fixed module (2), pressurizing and maintaining the pressure of the workpiece (3), and forming the compensator corrugation;
s23, moving the moving module (1), and opening the die for the workpiece (3);
and S24, moving the fixed module (2), and performing longitudinal die opening on the workpiece (3) to obtain the formed workpiece (3).
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GB769031A (en) * 1953-09-08 1957-02-27 Edward Joseph Poitras Improvements in or relating to bellows-forming method and apparatus
US5266021A (en) * 1991-10-10 1993-11-30 Jacobson Theodore L Apparatus for continuous forming of complex molded shapes
JPH09155461A (en) * 1995-12-04 1997-06-17 Sunami Seisakusho:Kk Corrugating device
JP2000079421A (en) * 1998-09-02 2000-03-21 Nhk Spring Co Ltd Device for manufacturing metallic bellows and manufacture of bellows
DE10027542A1 (en) * 2000-06-02 2001-12-13 Eurocopter Deutschland Metal bellows strength raising process involves shotblasting bellows after deformation in at least one region of inner flap
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