An improved procedure for manufacture of 3D tubes with springback concerned in flexible bending process

Three dimensional (3D) tubes, which possess the characteristics of space saving, lightweight and high strength, are widely used in many high-end industries such as aviation, aerospace, automobile and shipbuilding. However, when manufacturing a 3D tube in flexible bending process, springback is a big obstacle for improving the forming quality. In this paper, a new comprehensive strategy for springback control of 3D tubes is proposed. The strategy can be described as follows: (1) define the desired shape and manufacture shape; (2) optimize the manufacture shape using two tooling design methods (e.g. DA (displacement adjustment) method and B&T (bending and twisting) method presented in this paper); (3) make a discretization of the manufacture shape to acquire the optimized forming parameters. Additionally, experiment is implemented to validate the effectiveness of the new strategy. Results show that forming parameters acquired by the new strategy are partially effective. The new strategy also demonstrates that, during 3D tubes forming, the deviation caused by over-bent elements can be counteracted by the deficient-bent elements. This principle is helpful to reduce the difficulty of parameter determination in future.     

Plastic deformation analysis and forming quality prediction of tube NC bending

Plane strain assumption and exponent hardening law are used to investigate the plastic deformation in tube bending. Some theoretical formulae including stress, curvature radius of neu-tral layer, angle of neutral layer deviation, bending moment, wall thickness variation and cross-section distortion, are developed to explain the phenomena in tube bending and their magnitudes are also determined. During unloading process, the springback angle is deduced using the virtual work principle, and springback radius is also given according to the length of the neutral layer which remains unchanged before and after springback. The theoretical formulae are validated by the experimental results or the validated simulation results in literature, which can be used to quickly predict the forming quality of tube numerical control (NC) bending.     

挠性板弯折的数值分析方法

基于材料力学中梁弯曲的挠曲线方程,利用数值积分方法计算特定弯矩和剪力时挠性板的弯折曲线,同时利用曲线积分计算挠性板的长度,最终确定在给定长度和跨度情况下挠性板的弯折曲线以及对应的弯矩和剪力。利用有限元软件对相同模型在同一条件下进行模拟分析。将数值计算与有限元分析结果对比,发现两者变形曲线非常吻合,弯矩和剪力数值精度满足实际工程需求。基于上述数值计算方法,可以对挠性板弯折的各种参数进行分析和预估,对实际工程应用具有重要的指导意义。     

高深径比TC4钛合金筒形件普旋成型有限元数值模拟

采用有限元法对特定高深径比TC4钛合金筒形件普旋成型进行了数值模拟,分析了运动轨迹、旋压道次间距和间隙对成型的影响.结果表明普旋时坯料不同部位的应力应变状态不同,采用凹曲线轨迹,间隙为3.5 mm,首道次间距为9 mm,分6道次旋压成型效果好.同时在有限元数值模拟基础上,成功旋制了高精度试验件,说明有限元模拟对旋压具有很好指导意义.     

Modeling bending behavior of shape memory alloy wire-reinforced composites: Semi-analytical model and finite element analysis

In this study, we propose a novel and simple exact semi-analytical model for superelastic Shape Memory Alloy (SMA) wire reinforced composites subjected to bending loads. In order to study the mechanical response of the composite during loading/unloading, a Representative Volume Element (RVE) is extracted to examine the bending response of the composite. Analytical moment–curvature, and shear force-shear strain relations are derived based on a 3-Dimensional (3D) thermomechanical SMA model and Timoshenko beam theory. The composite Simpson’s rule is adopted to numerically solve the exact analytical moment–curvature and shear force-shear strain relationships. Results including the moment–curvature response, axial stress distribution along the vertical and longitudinal directions, martensite volume fraction, and the tip deflection are reported and validated against 3D finite element simulations. The influence of temperature, martensite volume fraction distribution, and matrix stiffness on the mechanical performance of the composite is also investigated. In particular, the composite is found to behave superelastically under certain conditions of temperature, SMA volume fraction, and elastic stiffness of the matrix. Such behavior is advantageous in applications requiring large recoverable strains or high energy dissipation density.     

Formability enhancement in hot spinning of titanium alloy thin-walled tube via prediction and control of ductile fracture

The damage and fracture in hot spinning of titanium alloy is a very complex process under the combined effects of microstructure evolution and stress state. In this study, their dependences on processing parameters were investigated by an integrated FE model considering microstructure and damage evolution, and revealing the effects of microstructure and stress states on damage evolution. The results show that the inner surface of workpiece with the largest voids volume fraction is the place with...     

22MnB5超高强钢板热成形中的回弹机理分析

回弹是影响热冲压件形状精度的主要因素,为研究影响22MnB5超高强钢板热冲压成形中回弹的因素,在不同温度下对22MnB5高强钢板进行拉伸试验,考察了变形温度和应变速率对弹性应变和蠕变应变的影响,获得其热力学性能。通过等温度和非等试验考察了变形温度、热成形终了温度和压边对热成形后回弹的影响。采用有限元法对槽形件非等温热成形过程进行了数值模拟。从试验结果和模拟结果可知,热效应是引起回弹的主要因素,蠕变应变减少了热成形后的回弹量。蠕变应变和热效应是影响热成形中回弹的主要因素。     

基于接触有限元的面齿轮传动弯曲强度研究

为了获得真实的面齿轮过渡曲面,推导了当插齿刀顶部为圆角时的过渡曲面方程.针对面齿轮齿面结构的特殊性,提出了有限元模型的"网格筛选法",纠正了单元形状的扭曲现象.以轮齿接触分析(TCA)为基础,采用三维接触有限元方法计算了面齿轮副的啮合过程中及其它参数变化时弯曲应力的变化.计算发现名义压力角参数和面齿轮轴向调整对弯曲强度都有重要影响.      

三维不可压流动有限元数值模拟

用原始变量带涡量的伽辽金有限元法计算三维定常不可压Ｎ－Ｓ问题，克服了过去由于速度和压力导数不同阶而不得不采用不同阶插值函数的困难。引入牛顿法线化Ｎ－Ｓ方程，使得用有限元离散后的大型代数方程组线性化，用高斯－赛德尔迭代法求解。算例为三维方穴驱动和带潜入锥的固体火箭发动机燃烧室轴对称加质流动。三维方穴驱动的计算结果与文献值相近。     

飞机风挡鸟撞击有限元数值模拟

应用接触碰撞有限元方法建立鸟撞击风挡三维分析模型,采用具有失效模型的率型材料本构模型,模拟飞机风挡鸟撞击动响应过程,给出两个风挡鸟撞的计算实例,并例结果说明了接触碰撞有限元方法的有效性,并且可更真实地揭示风挡结构被鸟冲击变形破坏的机理。     

圆管发动机法测定固体推进剂的泊松比

建立了一种测定固体推进剂泊松比的方法－圆管发动机法。测定了两种不同外内径比的圆管发动机药柱在固化降温后内孔的最大向形变量，以该形变量为依据，利用药柱在固化降温过程的有限元计算程序，拟合计算出该配合方药柱在固化降温后于不同温度下的泊松比，测定相对误差均不超过0．5％。     

复合材料胶接修补结构剩余强度分析

随着复合材料在航空结构中的广泛应用,航空复合材料修补技术也成为研究热点。通过复合材料单面胶接维修方法,将抛物线型损伤演化规律应用于胶层的损伤分析。对商业有限元软件进行了二次开发并建立了数值模型,研究了补片尺寸与厚度对修补结构压缩强度的影响。对复合材料胶接修补结构试验件进行剩余强度试验,研究了补片形状、尺寸、厚度等参数对修补后结构压缩剩余强度的影响。数值模拟结果与试验值吻合良好,误差在5%以内。     

尾喷管内外超声速流场数值模拟

采用有限元法数值模拟带二次流可调收－扩喷管内外跨声速和超声速流场，在计算中采用四边形等参元确定位移函数，利用加权余量法中的Galerkin法建立有限元方程，数值研究三种型式喷管和四种飞行工况下尾喷管内外流场。计算结果与实验数据符合较好，说明可用此数值模拟技术帮助开展实验研究，进行尾喷管优化设计。     

点焊钛合金蜂窝芯平压性能模拟研究

在对蜂窝芯力学性能的模拟研究中,常采用将双层壁之间的连接简化为双层壁厚的建模方法,但其不适用于点焊连接的钛合金蜂窝芯.本文提出利用LS-DYNA-EDWELD命令建立点焊连接蜂窝芯有限元模型的方法,对钛合金蜂窝芯进行平压模拟研究.同时,进行了钛合金蜂窝芯的平压力学性能试验,并将平压极限载荷值R.与模拟值进行了对比,结果显示点焊连接蜂窝芯有限元模型的平压模拟误差为6.5％,证明了此模型的准确性.最后,应用此模型得到了平压过程中焊点正拉和剪切力随位移的变化关系,研究了焊点正拉和剪切失效强度对蜂窝芯平压力学性能的影响,结果显示焊点正拉失效强度对蜂窝芯平压极限载荷的影响较大.     

燃烧条件下药柱脱粘扩展的设计

利用有限元方法分析了不同条件下药柱脱粘部位的应力状况,设计了复合固体推进剂燃烧条件下的脱粘扩展试件,通过X射线实时成像系统纪录了燃烧过程。结果表明:要形成脱粘扩展,脱粘部位装药要有大的拉伸变形;当药柱在点火冲击作用下,脱粘产生比较大的拉伸变形,且变形达到脱粘扩展的临界变形量时,就会出现脱粘扩展。     

基于CFD-DEM算法的固体火箭发动机气-固两相流模拟

针对固体火箭发动机中含金属推进体系中颗粒冲刷烧蚀及推力两相流损失的难题,基于连续相-离散元(CFD-DEM)耦合模型,考虑颗粒间的碰撞力与非碰撞力以及颗粒-气流作用力等,对固体发动机中气-固两相流进行了数值模拟研究。研究结果表明,相比于传统的双流体模型及轨道法,CFD-DEM能提供更丰富的粒子尺度信息包括粒子的运动轨迹、颗粒间的碰撞、颗粒受力情况等等;以及粒子相与气相相互作用过程,粒子相与壁面相互作用等。粒子的碰撞在喷管收敛段壁面、喉部区域以及喷管扩张段中心区域发生,与壁面的碰撞在收敛段壁面位置,且颗粒在该区域角速度较大,气相-颗粒曳力最大值出现在气相加速区域。单个粒子尺度的流场数据为固体发动机气固两相流流场的认识提供了更加丰富的信息,并为粒子聚集聚合及对烧蚀层冲刷等提供研究基础。     

Structural mass prediction in conceptual design of blended-wing-body aircraft

The Blended-Wing-Body (BWB) is an unconventional configuration of aircraft and considered as a potential configuration for future commercial aircraft. One of the difficulties in conceptual design of a BWB aircraft is structural mass prediction due to its unique structural feature. This paper presents a structural mass prediction method for conceptual design of BWB aircraft using a structure analysis and optimization method combined with empirical calibrations. The total BWB structural mass is divided into the ideal load-carrying structural mass, non-ideal mass, and secondary structural mass. Structural finite element analysis and optimization are used to predict the ideal primary structural mass, while the non-ideal mass and secondary structural mass are estimated by empirical methods. A BWB commercial aircraft is used to demonstrate the procedure of the BWB structural mass prediction method. The predicted mass of structural components of the BWB aircraft is presented, and the ratios of the structural component mass to the Maximum TakeOff Mass (MTOM) are discussed. It is found that the ratio of the fuselage mass to the MTOM for the BWB aircraft is much higher than that for a conventional commercial aircraft, and the ratio of the wing mass to the MTOM for the BWB aircraft is slightly lower than that for a conventional aircraft.     

低温环境下固体火箭发动机药柱伞盘结构设计

为提高固体火箭发动机伞盘药型药柱的低温力学性能,可通过调整伞盘药型来缓解其应力应变集中水平。以某固体火箭发动机药柱前伞盘为例,应用三维粘弹性有限元分析方法,分析不同前伞盘药型结构发动机的低温应变场,得到药柱前伞盘最大VonMises应变随伞盘药型结构变化的规律,结果表明药柱伞盘宽度的变化对伞盘顶部应力应变集中的影响最大。再综合考虑内弹道性能和浇铸工艺的要求可确定药柱前伞盘的最佳结构。该方法可为固体火箭发动机药型设计提供定量参考。     

燃烧条件下影响推进剂脱粘面扩展的因素

研究了固体火箭发动机推进剂与包覆层界面脱粘在燃烧条件下扩展的影响因素。对含有预制脱粘面的试件进行了大量的燃烧试验，用X射线实时成像系统记录了燃烧过程；根据组成试件的不同材料特性，分别用粘弹性和线弹性有限元方法计算了试件在燃烧过程中的应力应变状态，并利用修正后J积分法对脱粘面扩展的可能性进行了预估。理论分析和试验结果均表明：燃烧室增压速率、脱粘面尺寸、边界条件等因素对脱粘面扩展均有较强的影响。该研究结果对制定固体火箭发动机装药失效判据有一定参考价值。     

固体火箭发动机药柱伞盘结构应力应变分析

应用三维粘弹性有限元分析方法,分析了某固体火箭发动机药柱在低温载荷作用下的应力应变场,讨论了前伞盘曲面形式、宽度和深度对该部位最大Von Mises应变值的影响。在此基础上,通过调整前伞盘顶端双圆弧曲面结构的半径比,在基本不减少装药量的前提下,有效降低了该处最大Von Mises应变值,并初步确定了最佳半径比的范围,所得结论可为固体火箭发动机装药设计提供定量参考。