工程科学学报，第39卷，第7期：1077-1086,2017年7月 Chinese Journal of Engineering,Vol.39,No.7:1077-1086,July 2017 D0l:10.13374/j.issn2095-9389.2017.07.014:http://journals..ustb.edu.cn 一种板材小圆角胀压复合成形工艺解析 王耀，郎利辉⑧，孙志莹，阚鹏 北京航空航天大学机械工程及自动化学院，北京100191 ☒通信作者，E-mail:lang@buaa.edu.cm 摘要针对薄壁板材零件小圆角特征成形制造难的问题，提出了一种新型胀压复合成形工艺.其关键工艺参数为：预成形 高度、预成形凹圆角大小和终成形胀形压力与背压凸模运行速度匹配关系·预成形高度决定了终成形小圆角的材料储备，预 成形凹圆角的最佳值为充液拉深时凸模圆角可取的最小值，通过理论分析给出了预成形高度和预成形凹圆角的计算方法. 建立了胀压复合成形过程力学模型，通过应力状态分析给出了不同胀形压力与背压凸模运行速度匹配关系下坯料圆角区变 形状况.同时基于有限元模拟和工艺试验，研究了预成形高度和终成形胀形压力与背压匹配路径对试验件成形质量的影响， 验证了理论分析的准确性，并证明了该新工艺的适用性 关键词板材零件：小圆角特征：充液成形：胀压匹配：预成形高度：预成形凹圆角 分类号TG394 Analysis of a bulging-pressing compound-forming process for the sheet metal part with a small round corner feature WANG Yao,LANG Li-hui,SUN Zhi-ying,KAN Peng School of Mechanical Engineering and Automation,Beihang University,Beijing 100191,China Corresponding author,E-mail:lang@buaa.edu.cn ABSTRACT This study presented a new bulging-pressing compound-forming process to solve the manufacturing problem of a thin- wall specimen with a small round comner radius.Its key process parameters were the pre-forming depth,pre-forming concave round corner,and matching relation between the liquid bulging pressure and the backpressure punch velocity in the final forming process. The pre-forming depth determines the material reserves of the small round corner area in final forming.The best pre-forming concave round corner is the minimum punch comer in hydro-mechanical deep drawing.The calculating methods for the pre-forming depth and the pre-forming concave round corner were provided by a theoretical analysis.The mechanical model of the bulging-pressing compound forming process was built.Moreover,the deformation situation in the round corner area with different matching relations between the liquid bulging pressure and the backpressure punch velocity was provided by the stress state analysis.Meanwhile,the influences of the pre-forming depth and the matching relation between the liquid bulging pressure and the backpressure in final forming on the quality of the part were researched based on the finite element simulations and experiments.The accuracy of the theoretical analysis was verified. In addition,the applicability of the new process was proven. KEY WORDS sheet part;small round comner feature;hydroforming:bulging-pressing matching:pre-forming depth;pre-forming concave round corner 随着国家战略需求及先进制造技术的不断发展，月球车“玉兔号”，需承受月球表面真空、强辐射、极限 越来越多的产品将会在极端条件下运行，如中国首辆 温度(-180~150℃)等极端环境0.这种情况下，就 收稿日期：201607-22 基金项目：国家科技重大专项资助项目(2014ZX04002041):国家自然科学基金资助项目(51175024)工程科学学报，第 39 卷，第 7 期: 1077--1086，2017 年 7 月 Chinese Journal of Engineering，Vol． 39，No． 7: 1077--1086，July 2017 DOI: 10． 13374 /j． issn2095--9389． 2017． 07． 014; http: / /journals． ustb． edu． cn 一种板材小圆角胀压复合成形工艺解析 王 耀，郎利辉，孙志莹，阚 鹏 北京航空航天大学机械工程及自动化学院，北京 100191 通信作者，E-mail: lang@ buaa． edu． cn 摘 要 针对薄壁板材零件小圆角特征成形制造难的问题，提出了一种新型胀压复合成形工艺． 其关键工艺参数为: 预成形 高度、预成形凹圆角大小和终成形胀形压力与背压凸模运行速度匹配关系． 预成形高度决定了终成形小圆角的材料储备，预 成形凹圆角的最佳值为充液拉深时凸模圆角可取的最小值，通过理论分析给出了预成形高度和预成形凹圆角的计算方法． 建立了胀压复合成形过程力学模型，通过应力状态分析给出了不同胀形压力与背压凸模运行速度匹配关系下坯料圆角区变 形状况． 同时基于有限元模拟和工艺试验，研究了预成形高度和终成形胀形压力与背压匹配路径对试验件成形质量的影响， 验证了理论分析的准确性，并证明了该新工艺的适用性． 关键词 板材零件; 小圆角特征; 充液成形; 胀压匹配; 预成形高度; 预成形凹圆角 分类号 TG394 Analysis of a bulging-pressing compound-forming process for the sheet metal part with a small round corner feature WANG Yao，LANG Li-hui ，SUN Zhi-ying，KAN Peng School of Mechanical Engineering and Automation，Beihang University，Beijing 100191，China Corresponding author，E-mail: lang@ buaa． edu． cn ABSTＲACT This study presented a new bulging-pressing compound-forming process to solve the manufacturing problem of a thin￾wall specimen with a small round corner radius． Its key process parameters were the pre-forming depth，pre-forming concave round corner，and matching relation between the liquid bulging pressure and the backpressure punch velocity in the final forming process． The pre-forming depth determines the material reserves of the small round corner area in final forming． The best pre-forming concave round corner is the minimum punch corner in hydro-mechanical deep drawing． The calculating methods for the pre-forming depth and the pre-forming concave round corner were provided by a theoretical analysis． The mechanical model of the bulging-pressing compound forming process was built． Moreover，the deformation situation in the round corner area with different matching relations between the liquid bulging pressure and the backpressure punch velocity was provided by the stress state analysis． Meanwhile，the influences of the pre-forming depth and the matching relation between the liquid bulging pressure and the backpressure in final forming on the quality of the part were researched based on the finite element simulations and experiments． The accuracy of the theoretical analysis was verified． In addition，the applicability of the new process was proven． KEY WOＲDS sheet part; small round corner feature; hydroforming; bulging-pressing matching; pre-forming depth; pre-forming concave round corner 收稿日期: 2016--07--22 基金项目: 国家科技重大专项资助项目( 2014ZX04002041) ; 国家自然科学基金资助项目( 51175024) 随着国家战略需求及先进制造技术的不断发展， 越来越多的产品将会在极端条件下运行，如中国首辆 月球车“玉兔号”，需承受月球表面真空、强辐射、极限 温度( － 180 ～ 150 ℃ ) 等极端环境［1］． 这种情况下，就