钛合金薄壁环件制造过程残余应力与加工变形模拟与优化

王天乐; 邓加东; 钱东升; 丁佐军; 刘超

doi:10.7513/j.issn.1004-7638.2026.02.002

钛合金薄壁环件制造过程残余应力与加工变形模拟与优化

doi: 10.7513/j.issn.1004-7638.2026.02.002

王天乐^{1, 2,},
邓加东^{1, 2, 3, ,},
钱东升^{1, 2, 3},
丁佐军⁴,
刘超⁴

1.
武汉理工大学高温轻合金及应用技术全国重点实验室, 湖北武汉 430070
2.
武汉理工大学现代汽车零部件技术湖北省重点实验室, 湖北武汉 430070
3.
武汉理工大学湖北省材料绿色精密成形工程技术研究中心, 湖北武汉 430070
4.
无锡派克新材料科技股份有限公司, 江苏无锡 214000

基金项目: 国家重点研发计划项目（2024YFB3714200）；国家自然科学基金资助项目（52475397）；高等学校学科创新引智计划资助项目（B17034）；教育部创新团队发展计划项目（No. IRT_17R83）。

详细信息

作者简介:
王天乐，2001年出生，男，陕西汉中人，硕士研究生，主要研究方向为钛合金成形制造，E-mail：1634482910@qq.com

通讯作者:
邓加东，1988年出生，男，湖北武汉人，副教授，博士，主要研究方向为环类零件成形制造理论与技术，E-mail：dengjd@whut.edu.cn

中图分类号: TF823，TG146.2
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出版历程
- 收稿日期: 2025-12-31
- 录用日期: 2026-02-03
- 修回日期: 2026-01-22
- 网络出版日期: 2026-04-20
- 刊出日期: 2026-04-20

Simulation analysis and process optimization of residual stress and machining deformation in the manufacturing of thin-walled titanium alloy rings

WANG Tianle^{1, 2
,},
DENG Jiadong^{1, 2, 3
, ,},
QIAN Dongsheng^{1, 2, 3},
DING Zuojun⁴,
LIU Chao⁴

1.
National Key Laboratory of High Temperature Light Alloys and Application Technology, Wuhan University of Technology, Wuhan 430070, Hubei, China
2.
Hubei Key Laboratory of Modern Automotive Components Technology, Wuhan University of Technology, Wuhan 430070, Hubei, China
3.
Hubei Engineering Technology Research Center for Green Precision Material Forming, Wuhan University of Technology, Wuhan 430070, Hubei, China
4.
Wuxi Paike New Materials Technology Co., Ltd. , Wuxi 214000, Jiangsu, China

摘要

摘要: 钛合金薄壁环件是航空航天等领域的关键构件，其机加工变形严重制约精度与可靠性。以钛合金矩形薄壁环件为对象，建立了轧制、冷却、加热、胀形及热处理全流程有限元模型，系统研究了成形过程残余应力演变规律及其对机加工变形的影响。通过分析不同胀形量与胀形温度下的应力分布特征，揭示了胀形工艺对应力场的调控机制，在此基础上，构建了残余应力与加工变形之间的理论分析模型，并进行了仿真与试验验证。结果表明，环件残余应力主要产生于首次冷却阶段，后续胀形及热处理工序可显著降低应力幅值并改善分布均匀性；合理的胀形工艺可有效改善残余应力分布，其中胀形量约4%、胀形温度800 ℃时应力水平最低且分布最为均匀；机加工仿真结果与理论模型计算结果吻合良好，最大误差为20.37%。进一步将优化工艺与理论模型应用于异形环件，并通过试验验证其有效性与工程适用性。研究结果可为钛合金薄壁环件残余应力调控及加工变形控制提供理论依据和工艺指导。
- 钛合金环件 /
- 胀形工艺 /
- 残余应力 /
- 机加工变形 /
- 有限元模拟
Abstract: Thin-walled titanium alloy rings are critical aerospace components, whose machining deformation severely restricts their dimensional accuracy and service reliability. A full-process finite element model covering rolling, cooling, heating, bulging and heat treatment was established for rectangular thin-walled titanium alloy rings, to systematically investigate residual stress evolution during forming and its effect on machining deformation. The regulation mechanism of bulging on the stress field was revealed by analyzing stress distribution under different bulging parameters, and a theoretical model correlating residual stress and machining deformation was constructed and verified via simulation and experiments. Results show that residual stress mainly originates from the initial cooling stage, and subsequent bulging and heat treatment can significantly reduce stress amplitude and improve distribution uniformity. The optimal residual stress state is achieved at a bulging ratio of 4% and a bulging temperature of 800 °C. Simulation results are in good agreement with theoretical calculations, with a maximum error of 20.37%. The optimized process and model were validated effective for special-shaped rings, providing a theoretical basis and process guidance for residual stress regulation and deformation control of titanium alloy thin-walled rings.
- titanium alloy ring /
- bulging process /
- residual stress /
- machining deformation /
- finite element simulation

HTML全文

图 1 轧制和胀形有限元模型

(a)轧制模型; (b)胀形模型

Figure 1. Rolling and bulging finite element model

下载: 全尺寸图片幻灯片

图 2 机加工有限元模型

Figure 2. Machining finite element model

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图 3 机加工模拟与试验结果对比

(a)上端面; (b)内壁; (c)外壁

Figure 3. Comparison of machining simulation and experimental results

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图 4 制造关键工序中环件应力演化规律

(a)轧制; (b)冷却; (c)加热; (d)胀形; (e)卸载冷却; (f)热处理; (g)冷却

Figure 4. Stress evolution law of ring-shaped components in key manufacturing processes

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图 5 环件各工序周向残余应力评价指标

(a)均值; (b)标准差和梯度

Figure 5. Evaluation indices of circumferential residual stress

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图 6 不同胀形量下胀形后环件各位置的应力评价指标

(a)上端面; (b)内壁; (c)外壁

Figure 6. Stress indices of bulged ring at different bulging ratio

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图 7 不同胀形温度下胀形后环件各位置的应力评价指标

(a)上端面; (b)内壁; (c)外壁

Figure 7. Stress indices of bulged ring at different bulging temperatures

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图 8 胀形工艺参数对仿真和理论计算的椭圆度影响

(a)胀形量; (b) 胀形温度

Figure 8. Simulation and theoretical calculation of machining deformation

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图 9 异形环件尺寸（单位：mm）

Figure 9. Dimensions of the special-shaped ring component

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图 10 异形环件胀形后模拟和试验结果

(a)仿真; (b)试验

Figure 10. Simulation and experimental results of special-shaped ring components

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图 11 胀形后环件不同部位残余应力结果

Figure 11. Post-bulging residual stress results at different positions of ring components

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表 1 TC4钛合金环件轧制工艺参数

Table 1. Process parameters of TC4 titanium alloy ring component

Size of ring blank/mm	Size of rolled ring/mm	Speed of driving roll/(rad·s⁻¹)	Speed of the mandrel/ (mm·s⁻¹)	Initial temperature of roll/℃	Bulging speed/ (mm·s⁻¹)	Coulomb friction factor	Ambient temperature/℃	Initial temperature of blank/℃
Ø72×Ø45×15	Ø106×Ø90×15	0.8	0.5	300	1	0.6	25	950

下载: 导出CSV

表 2 TC4钛合金环件胀形参数

Table 2. Expansion parameters of TC4 titanium alloy ring component

Number	Bulging ratio/%	Temperature/℃
A-3	2	800
B-3	4	800
C-3	6	800
C-2	6	700
C-1	6	600

下载: 导出CSV

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