关键词: 薄壁锥形筒件, 轧制成形, 变形状态, 控制方法

Abstract:  In order to solve the problems of difficult control of geometric deformations in roll-forming processes of aerospace thin-walled conical cylinders， three typical abnormal deformation states and formation mechanism of thin-walled conical cylinders were revealed， such as axis deviation， axis tilt and small end retraction. A conical roller motion coordination control method was proposed based on linear velocity feedback of cylinders， and a conical roller motion control model was established. The billet optimization design methods of thin-walled conical cylinders were proposed， and the corresponding core roll inclined feed control strategies were established， which ensured the consistency of the diameter growth rate of conical cylinders and eliminated the small end shrinkage phenomenon caused by the mismatch between the axial and circumferential flows of metal. The finite element models of thin-walled conical cylinder rolling with improved control methods and strategies were established based on ABAQUS software and VUAMP subroutine development. The forming effect of the cone rolling processes under conventional planning control， independent control and comprehensive control was compared and analyzed. The results show that the indexes such as axis offset， roundness error， concentricity error and inclination angle error of cylinder using the comprehensive control method are reduced by 93.6%， 75.3%， 95.1% and 97.2% in the modulation stage， respectively， compared with the conventional planning control. 

Key words: thin-walled conical cylinder, roll-forming, deformation state, control method