面向残余应力变形的铝合金薄壁圆盘结构优化

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关键词：7A04铝合金；薄壁圆盘；残余应力；变形控制；有限元仿真；结构优化中图分类号： 文献标志码：A

Structural optimization of aluminum alloy thin-walled disk for residual stress deformation

AN Xiao1.2， ZHOU Yuke’，QIQi²， ZHAO Chaoqun²， CAI Xinyi²， ZHOU Jinhua² （1. Xi'an Branch， China Academy of Space Technology， Xi'an71oooo， China; 2.School of Mechanical Engineering， Northwestern Polytechnical University， Xi'an 7loo72， China）

Abstract： Aluminum alloy thin-walled disk components， as the core structure of a satelite detector antenna， require extremely high flatness， and the current milling level often fails to meet design requirements. To address the issue of excessive deformation of 7A04 aluminum alloy thin-walled disk during miling caused by residual stress coupling effects， a deformation suppression method integrating structural design and process control was proposed. First， the distribution paterns of initial internal stresses and milling residual stress gradients in 7A04 aluminum alloy were obtained. Second， using theAbaqus finite element platform， a deformation simulation model for the thin-walled disk under the coupled efects of initial/milling residual stresses was established. Then， a deformation-resistant optimization design for the 7A04 aluminum aloy thin-walled disk structure was conducted. Finally， through thin-walled disk machining experiments， the effectiveness of the structural optimization scheme was verified， and it was found that the flatness of the thin-walled disk reached 0.103mm . Consequently， a collaborative control methodology comprising “stress distribution detection-deformation simulation modelling-deformation-resistant structural design” was formed. This approach efectively suppresses coupled deformation arising from initial and residual milling stresses， providing an effective technical solution for the precision manufacturing of aerospace thin-walled components.

Keywords： 7AO4 aluminum alloy; thin-walled disk; residual stress; deformation control; finite element simulation; structural optimization

7A04铝合金因其高比强度、优异的耐腐蚀性能和良好的工艺适应性，已成为航天器天线结构中的关键材料，尤其在某卫星探测器天线核心结构中得到广泛应用。（剩余12140字）