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针对现代技术无法直接成形的相对弯曲半径r/D≤1、相对壁厚t/D≤0.05的弯头零件,提出了一种弯胀成形工艺。该工艺将数控弯管技术与充液成形技术相结合,旨在消除传统半管对焊工艺中的焊缝,实现薄壁小半径弯头的整体成形。采用全过程数值分析方法和正交试验方法,研究了弯胀成形工艺的可行性以及关键参数的选取问题。研究结果表明,数控弯管技术使零件的预成形快速且稳定,充液成形技术有效提高了零件的成形极限,弯胀成形工艺对薄壁小半径弯头的制造行之有效。
Aiming at the elbow parts with relative bending radius r / D≤1 and relative wall thickness t / D≤0.05, which can not be directly formed by modern technology, a bulging forming process is proposed. The process combines the numerical control elbow technology and the liquid filling forming technology to eliminate the weld in the traditional semi-pipe butt welding process and achieve the overall forming of the thin-wall small-radius elbow. The whole process of numerical analysis and orthogonal test methods were used to study the feasibility of the bulging forming process and the selection of the key parameters. The results show that CNC pipe bending technology makes the preform forming fast and stable, and the liquid filling forming technology can effectively increase the forming limit of the part. The forming process of the thin wall and small radius bend is effective.