塑性失稳诱发起皱是制约薄壁曲面构件整体成形的瓶颈问题，通过考虑悬空区反胀效果的曲面薄壳流体压力成形力学分析，推导抑制起皱和破裂的非线性流体压力加载曲线，建立临界起皱应力模型为塑性失稳提供理论判据；在此基础上，针对大型贮箱整体箱底构件流体压力成形起皱预测和控制难题，理论计算大型箱底流体压力成形加载路径，分析流体压力加载路径对反胀区形状、失稳行为和应力分布影响规律，揭示曲面薄壳流体压力成形起皱抑制机理；采用我国自主研制的超大型数控流体压力成形装备（成形力1.5万t/高压液体体积5 m3），首次试制出直径3 m级运载火箭燃料贮箱整体箱底，解决了大型超薄（厚径比2‰）曲面薄壳失稳难题。
刘伟
,
徐永超
,
陈一哲
,
苑世剑
,
胡蓝
,
张志超
,
郭立杰
. 薄壁曲面整体构件流体压力成形起皱机理与控制[J]. 机械工程学报, 2018
, 54(9)
: 37
-44
.
DOI: 10.3901/JME.2018.09.037
Wrinkling induced by plastic instability is a critical problem for the forming of integral thin-walled curved shells. Considering the reverse bulging effect in unsupported area, the mechanical characteristics of sheet hydroforming process is analyzed. Loading paths of liquid pressure about wrinkling and rupture are deduced, a model about critical wrinkling stress is built which can be regarded as a criterion for the plastic instability. Focusing on the forming process of storage tanks of rockets, a theoretical loading path is calculated, the influence of loading path on bulging geometry, instability behavior and stress distribution is discussed. The mechanism of wrinkling suppression is revealed. A large numerical control sheet hydroforming equipment with the biggest power in the world was successfully built (forming power 15000 t, volume of high pressure liquid 5 m3). An integral storage tank with diameter of 3m is successfully obtained using the proposed method and equipment. The problem on plastic instability of thin-walled shell (ratio of thickness to diameter equals 2‰) is solved.
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