某大型空间航天器带法兰异构壁板精密成形工艺研究

针对某大型空间航天器带法兰异构壁板薄厚不一致、刚度不均匀、在成形过程中容易产生断裂的难题,利用ABAQUS对整体壁板压弯成形过程进行了有限元分析,讨论了直接压弯成形过程中易产生缺陷的部位和原因。结果表明,壁板直接压弯成形加强筋及其交汇处应力集中,应力值最大,为成形过程的薄弱区,容易产生失稳及断裂。针对该情况,提出了柔性补强压弯成形工艺方法,并进行了成形工艺实验验证,实验结果表明,采用该方法成形的壁板蒙皮与加强筋表面质量良好,曲率均匀,无缺陷,满足尺寸精度要求;最后,在有限元模拟及工艺验证实验的基础上,利用柔性补强技术和分段压弯成形技术相结合的方法,解决了带法兰异构壁板传统成形法兰过渡处易断裂的成形难题,实现了该大型空间航天器多种带法兰异构壁板的成形制造。     

大型铝合金整体壁板压弯成形工艺研究

本文利用ABAQUS有限元分析软件,基于Mises屈服准则和动态显式算法模拟了铝合金整体壁板压弯成形过程,研究了压弯成形过程中铝合金整体壁板的应力应变状态,分析了整体壁板压弯成形中易产生缺陷的部位及原因.为避免缺陷产生,提出了聚氨酯橡胶填块压弯成形工艺方法,并进行了成形实验研究.     

异型截面铝合金管件内高压成形

对空心异型截面弯曲轴线铝合金零件内高压成形进行了工艺实验与数值模拟.采用压弯与内高压成形的工艺步骤成形零件,测量了成形零件典型截面的尺寸与壁厚分布,通过数值模拟分析了变形过程中的等效应力与壁厚分布.经检测成形零件外形尺寸与壁厚均符合设计要求,但典型截面壁厚分布不均匀.     

扫描次数对板料激光弯曲成形影响的有限元仿真研究

采用有限元方法实现了激光弯曲成形多次重复扫描过程的仿真。研究了板料上下表面的应变、温度等随时间的变化规律,结果表明:板料的弯曲角度与扫描次数间基本保持线性关系,而且第一次扫描板料产生的弯曲角度最大。     

型材拉弯回弹有限元分析

对两种不同截面的铝型材分别在6种不同拉弯成形工艺中的拉弯过程进行有限元数值模拟,探讨成形工艺、弯曲半径与型材截面形状对拉弯成形后型材回弹的影响。     

TA2M钛板扩孔成形中的形状畸变现象研究

通过有限元数值模拟和工艺试验相结合的方法对板料厚度为0.96mm的TA2M钛板的扩孔成形过程及结果进行了研究.运用PAM-STAMP有限元数值模拟分析软件对成型过程及卸载回弹结果进行预测.发现TA2M在成型卸载回弹后存在明显的形状畸变现象:孔口非圆化,孔口边缘厚度非均匀减薄以及凸缘非圆化.模拟预测结果与工艺试验结果比较吻合.     

基于解耦计算的多步快速成形有限元法

钣金零件是构成飞机机体和汽车车身的重要零部件。为缩短钣金件的生产周期,将有限元法用于零件设计初期评估零件的可制造性。为提高现有板料成形有限元法的计算效率,同时保证模拟精度,在一步快速成形有限元法的理论基础上,研究多步快速成形有限元法,通过引入中间构形的方式来考虑板料成形过程中加载路径与变形历史的影响。中间构形的构造是多步快速成形有限元法的关键,采用解耦思想将中间构形分解为弯曲变形和拉伸变形两个独立的过程进行计算。在弯曲变形阶段,不考虑材料的流动,根据板料与模具之间的位置关系计算获得滑移约束面;在拉伸变形阶段,材料的流动限制在滑移约束面上,通过应力平衡迭代以及节点修正后获得中间构形。以典型的钣金零件为例进行成形模拟,与现有商业有限元软件在计算精度和效率上进行对比,验证了该算法的可行性和有效性。结果表明,所提出的算法能够快速地构造出合理的中间构形,且能够准确地预测零件的成形性和厚度分布。     

基于宏模板技术的橡皮囊成形仿真研究

橡皮囊成形是飞机钣金件的一种重要成形工艺方法。有限元数值模拟技术越来越多地被用于分析板料成形过程中可能存在的问题。本文针对目前大多数有限元软件没有针对橡皮囊成形模块的现状,基于橡皮囊成形工艺,应用PAM-STAMP 2G软件提供的开发宏模板的功能,以一个典型的钛合金钣金零件为例,研究钛合金钣金零件橡皮囊成形仿真技术,为飞机钛合金钣金零件的橡皮囊成形设计和生产提供依据。     

铝合金壁板筋条多点对压成形失稳及断裂研究

应用多点模具对压成形铝合金整体壁板是一种新技术,如何预测和避免筋条的失稳和断裂是该技术能否用于实际生产的关键问题之一。针对铝合金壁板筋条的多点弯曲过程,提出了失稳和断裂的判定方法,应用有限元模拟和多点压弯试验进行了对比分析。结果表明,失稳和断裂判定方法能够预测筋条产生失稳和断裂的位置和时刻。基于多点模具形状调整快的特点,采用分道次成形的方式研究了压弯半径对筋条断裂和失稳的影响规律,确定了单筋条多点压弯时的极限曲率半径。模拟了复杂结构整体壁板在变路径加载条件下的失稳和断裂情况,优化了加载路径。     

板料气压成形过程的数值模拟和压力优化设计

介绍了采用刚－粘塑性有限元技术模拟板料气压成形过程，提出在数值模拟预测成形过程的基础上优化设计压力载荷的方法，利用此法求出的Ｐ－ｔ曲线可供生产实际采用。文末还给出了模拟圆盘件经正反吹成形过程的实例。     

钛合金板材激光弯曲成形的研究

 对常温下钛合金板材进行了激光弯曲成形研究。分析了激光功率、扫描速度、光斑大小对板材弯曲变形的影响,获得理想工艺参数范围为:功率1 .0～1 .2 k W、扫描速度2～3 m/min、光斑直径6～7mm。同时分析了板材厚度、宽度及扫描次数对材料弯曲变形的影响,为钛合金板材弯曲成形提供了一种新途径。     

Impact of bending dies with different friction forms on forming force and quality of tubes manufactured by free bending technology

In the 3D free bending forming system, the bending die can be designed either in a sliding type or rolling friction type. Bending die-based sliding friction type is often called normal bending dies; however, the bending dies-based rolling friction type includes bending die-based roller type and ball type in structure. In the current study, the impact of three bending dies on the forming force, and the bent tube quality was investigated. The obtained results showed that the tangential stresses and strains of the tubes formed by the bending die-based roller type were the smallest among the three bending dies. Besides, the spherical bearing force P_U was reduced drastically after using the roller type and ball type compared to the sliding friction type. Moreover, the uniformity of the wall thickness distribution of the tubes formed by the roller type and ball type was better than those obtained from the sliding friction type. In addition, the cross-section distortion rate was reduced by 2.8% using the roller type, and 1.8% using ball-type compared to the sliding friction type.     

变摩擦控制厚度分布的TC4深筒形件正反向超塑成形

以正反向超塑成形厚度均匀的TC4钛合金深筒形件为背景,采用MARC有限元模拟分析了正反向超塑成形时预成形模和终成形模的表面摩擦系数对成形件壁厚分布的影响.结果表明:合理地增大预成形模的表面摩擦力能显著增加预成形的局部减薄作用,对于提高零件最终壁厚分布均匀性有利.同时,合理减小终成形模的摩擦力,可以使板料褴体变形均匀化,壁厚分布趋于均匀.根据模拟结果,采用机械加工方法增加预成形模表面粗糙度以增大摩擦力,在终成形模表面喷涂润滑剂以降低摩擦力,通过正反向超塑成形实验制得厚度分布在1.50～1.78mm范围内的航天用TC4钛合金深简形件,比普通正反向超塑成形件厚度分布(1.18～2.24mm)有了很大改善.     

圆棒热挤压过程研究

用抛物面速度场,对圆棒热挤压过程进行上限分析。经理论计算和有关试验数据比较,所求得的挤压力具有足够高的精度;并利用所建立的数学模型对挤压过程死区、最佳模角和挤压力进行了系统地研究。     

TB5钛合金薄板微观组织与弯曲性能关系研究

TB5钛合金板材具有优良的冷成形性能,适于成形中等复杂的航空航天用板材零件,但存在板材定形性差、成形后回弹大等问题。本文以TB5钛合金板材的冷成形为背景,探讨了TB5钛合金板材组织在弯曲变形过程中的变形行为及其微结构和成形性能的演变规律。结果表明,随着板材弯曲角度的增大或弯曲半径的减小,板材弯曲回弹角与中心变形处晶粒面积和晶粒横纵比正相关;板材中心变形处硬度和中心变形处晶粒面积正相关,与中心变形处晶粒横纵比负相关。     

Design of an innovative multi-stage forming process for a complex aeronautical thin-walled part with very small radii

In this paper, an aeronautical thin-walled part with a complex geometry which has several sharp bends and curvatures in different directions was investigated. This kind of part is difficult to be manufactured only in one stage. Therefore, an innovative multi-stage active hydroforming process assisted by the rigid forming method was designed. In addition, an optimized blank geometry is obtained. In fact, the main focused point of this paper is to propose a new small radius rounded corner forming technique and analyze the mechanism. Two kinds of forming modes of changing a big rounded corner into a small one, which are related to different tangential positions of the die in the process of calibration, are analyzed theoretically. Meanwhile, the stress and strain states of the deformation region are compared. The relationships between the minimum relative radii of rounded corners I and II in the first stage and the hydraulic pressure are calculated by the bending theory. Finally, the influences of the tensile-bulging effect and the interface condition of the double-layer sheet on the forming quality of the specimen are investigated. The achieved results can make a foundation for utilizing the proposed method in forming of thin-walled parts with very small radii.     

基于UG曲轴锻造模具设计

通过分析复杂多拐曲轴零件的锻造工艺特点,确定了成型工艺方案;运用UG对曲轴进行三维建模,完成了滚挤、弯曲、预锻和终锻模具的设计;实现了曲轴模具的数字化设计,达到模具设计要求、试模一次成功。     

Experimental and numerical investigation on surface quality for two-point incremental sheet forming with interpolator

The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming (ISF) in industrial field. As a novel approach, the interpolator method is a promising strategy to enhance the surface quality in ISF. However, the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood. In this paper, the influences of process variables (i.e. tool diameter, step size and thickness of interpolators) on the forming process (e.g. surface roughness, forming force and geometric error) are investigated through a systematic experimental approach of central composite design (CCD) in two-point incremental sheet forming (TPIF). It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path. Nevertheless, the combined influence between thickness of interpolators and process parameters (tool diameter and step size) is limited. Meanwhile, the placement of interpolator has little influence on the effective forming force of blank. In addition, the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter. Finally, the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of the contact pressure due to the increase of contact area with the unchanged contact force. Meanwhile, the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.     

On a plastic instability criterion for ultra-large radial-axial ring rolling process with four guide rolls

A dynamic mechanical model is proposed to describe the complexing actions of all the rolls on the ring during the ultra-large radial-axial ring rolling(RARR) process with four guide rolls. Based on the model, the calculation models for bending moment and normal stress at any section of the ring are deduced by force method. If the maximum section bending normal stress exceeds the yield stress of the ring materials, the ring will be distorted thus leading to the instability of the RARR process. Ac...     

薄板几何尺寸对等离子电弧加热弯曲成形的影响

主要研究等离子电弧加热弯曲成形过程中薄板的厚度、长度、宽度以及薄板扫描线距自由端的距离等对等离子电弧弯曲成形的影响。