(1. 燕山大学 先进锻压成形技术与科学教育部重点实验室，秦皇岛 066004；
2. 北京动力机械研究所，北京 100074；
3. 燕山大学 车辆与能源学院，秦皇岛 066004)
摘 要: 针对某航空发动机高温合金GH3044薄壁管凸环零件的成形难题，采用固体颗粒介质成形(SGMF)工艺，基于管材成形过程的塑性力学分析和有限元数值仿真，优化工艺方案，设计并制造模具，试制合格零件。采用有限元软件ABABQUS平台下的Drucker-Prager模型描述固体颗粒介质所特有的离散性摩擦材料特征，建立成形工艺有限元数值仿真模型、优化管端轴向进给力和介质成形力的匹配关系，得到轴向进给力对零件减薄率、壁厚差以及型面轮廓的影响规律。采用水平分模和弹性进给式模具结构，在单动压力机上实现了合模、轴向进给及介质加载等多动作压制功能。
关键字: 高温合金；固体颗粒介质；管材成形；管端进给力；数值模拟
（1. Key Laboratory of Advanced Forging & Stamping Technology and Science,
Ministry of Education of China, Yanshan University, Qinhuangdao 066004, China;
2. Beijing Power Machineries Institute, Beijing 100074, China;
3. College of Vehicles and Energy, Yanshan University, Qinhuangdao 066004, China）
Abstract:To meet the challenge of forming high temperature alloy (GH3044) parts, solid granules medium forming (SGMF) process was adopted for forming a convex ring shaped tube that was used in the aircraft engine. Based on the plastic mechanical analysis and finite element numerical simulation of the forming process, the technology process was optimized and the moulds was manufactured and designed, with which the qualified parts were produced. Drucker-Prager model in the finite element software ABABQUS was adopted to describe frictional material characteristics peculiar to solid granules medium. Based on it, the finite element numerical simulation model of the SGMF process was established. Through the analysis, the best matching of the axial force and the medium loading force was optimized, and the influence law of axial force on reduction ratio, thickness difference and surface contour of the tube is found. With the mold structure of horizontal parting and flexibility feeding, the mould can do multiple actions, such as mold closing, axial feeding and medium loading with single press.
Key words: high temperature alloy; solid granular medium; tube forming; tube axial force; numerical simulation
