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

摘要： 针对航空航天薄壁锥形筒件轧制过程几何变形状态难以控制的问题，研究了薄壁锥形筒件轴线偏移、轴线倾斜、小端拉缩三种典型异常变形状态及形成机理，提出了基于筒件线速度反馈的锥辊运动协调控制方法，建立了锥形筒件轧制过程锥辊运动控制模型；提出了薄壁锥形筒件坯料优化设计方法，并建立了相应的芯辊倾斜进给控制策略，保证了锥形筒件直径长大速度的一致性，消除了因金属轴向和周向流动不匹配导致的小端拉缩现象；基于ABAQUS软件和VUAMP子程序开发，建立了集成所提控制方法和策略的薄壁锥形筒件轧制有限元模型。对比分析了常规规划控制、上述方法独立控制和综合控制下的筒件轧制成形效果，结果表明，综合控制方法下的轴线偏移量、圆度误差、同心度误差和倾斜角误差等指标相比于常规规划控制在整圆阶段内分别降低了93.6%、75.3%、95.1%、97.2%。

关键词: 薄壁锥形筒件, 轧制成形, 变形状态, 控制方法