中文摘要：

针对6061铝合金飞行器翼尖蒙皮零件采用充液成形工艺,可以有效避免在传统拉深中容易产生的起皱和破裂等缺陷。基于Dynaform模拟软件建立零件充液成形有限元模型,设计不同参数的工艺方案针对成形过程中的悬空区起皱进行分析,研究了压边间隙和液室压力工艺参数对起皱控制的影响规律。研究结果表明,在充液成形过程中,板料流动的均匀程度与悬空区板料平面内压应力的大小对起皱影响明显。压边间隙过大和过小均会导致零件悬空区出现起皱,液室压力在零件成形初期可以阻碍板料过快地向凹模内流动,成形中期和后期,液室压力可以一定程度上抵消板料平面内压应力的作用,抑制悬空区板料的起皱趋势。最后对模拟结果进行试验验证,试制出了合格的飞行器翼尖蒙皮零件。

英文摘要：

The wing tip skin of 6061 aluminium alloy was formed by hydroforming, which effectively avoided deficiencies such as wrinkling and fracture in traditional deep drawing. A numerical model of hydroforming was established by using Dynaform software. The inner wrinkle in the unconnected area during the hydroforming process was analyzed under the technology scheme of different technological parameters. The influence regularities of blank holder clearance and chamber pressure on wrinkle control were studied. The results show that the sheet flow uniformity and the compressive stress in-plane of connected area sheet have strong effects on the wrinkle control. The inner wrinkle on unconnected areas is caused by unsuitable blank holder clearance. The chamber pressure hinders the blank flowing into die too quickly at the beginning of the hydroforming process and offsets the compressive stress in-plane to a certain extent at the middle and later period of that process and inhibits wrinkling trend on connected areas. The simulation results are verified through the experimental results and qualified wing tip skin is produced.