轻量化结构件弯曲成形工艺研究
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摘要
轻量化是航空航天、轨道交通等行业一直追求的目标。铝合金整体壁板和镁合金复杂截面型材作为典型的轻量化结构件,在运载火箭、导弹、飞机以及汽车交通领域有着广泛的使用价值。这些行业所用的轻量化结构件为了追求整体结构的优越性能和提高气动力外形,往往需要将其弯曲成形为一定曲率外形。但是这些轻量化结构件属于典型的多筋零部件,结构形式复杂,传统弯曲成形过程中容易产生多种缺陷且成形件的几何精度差。因此,开展轻量化结构件的先进弯曲成形工艺研究十分必要。本文在分析具体轻量化结构件的基础上,提出了铝合金整体壁板的机械铣-填料辅助滚弯成形工艺和镁合金型材的温热张力绕弯成形工艺,采用理论分析、有限元数值模拟和实验相结合的方法系统研究了填料滚弯成形工艺和张力绕弯成形工艺过程。本文的主要研究内容和结论如下：
(1)研究整体壁板和型材的弯曲成形机理。系统分析整体壁板填料辅助滚弯的成形原理,分析了筋条内置和外置两种整体壁板筋条和蒙皮的力学状态、几何关系和回弹规律；研究镁合金型材温热张力绕弯成形原理,分析了型材内外侧不同特征位置的力学状态和回弹规律；理论分析为弯曲成形数学模型的建立提供了理论依据。
(2)采用单向拉伸试验获得材料的应力应变关系,基于MSC.Marc建立了铝合金整体壁板填料辅助滚弯成形的三维弹塑性有限元模型,分析了滚弯成形过程中整体壁板的应力应变变化和回弹规律,揭示了填料在滚弯成形过程中的机理。基于MSC.Marc建立了镁合金型材温热张力绕弯成形的三维弹塑性热力耦合有限元模型,分析了绕弯成形过程中型材的应力应变、温度、回弹和几何尺寸的变化规律。
(3)研制滚弯成形装置,设计并开发了成形工艺参数的数据采集系统；自主研制橡胶和塑料填料,进行了填料辅助整体壁板的滚弯成形实验,研究了填料和工艺参数对整体壁板表面质量和几何精度的影响。结果表明：研制的填料满足了整体壁板滚弯成形的要求,填料改变了壁板的受力状态,使蒙皮产生均匀的塑性变形,提高了蒙皮和筋条的变形协调性。随着上辊压下量的增大,壁板弯曲半径减小。当压下量较小时,、随着压下量的增大,壁板弯曲半径急剧减小；当压下量较大时,随着压下量的增大,弯曲半径减小幅度降低；基于最小二乘法获得的经验公式表明,压下量与弯曲半径呈幂指数函数关系。
(4)研制镁合金型材温热张力绕弯成形装置,进行镁合金型材温热张力绕弯成形实验,分析成形温度、弯曲角度和预拉伸量对型材回弹角和几何精度的影响,将实验结果与模拟结果对比分析；采用光学显微镜、X射线衍射仪和EBSD技术系统分析型材的微观组织和织构演变。结果表明：模拟结果和实验结果基本吻合,工艺参数对回弹和几何尺寸变化的影响规律一致,模拟结果可以用于指导实验。微观组织和织构变化规律表明：温热弯曲成形过程中,大量孪晶出现,改变了晶粒的初始取向,协调了晶粒c轴的应变,提高了型材的塑性变形能力。
Lightweight is the long-term goal of aerospace, rail transport and other industries. As the typical lightweight structures, the integral panel skins of aluminum alloys and complex cross-section profile of magnesium alloys have been widely used in the launch vehicles, missiles, aircrafts and automobile traffic. These lightweight structures are often bent to appearance with certain curvature in order to acquire the overall structure of superior performance and improve the aerodynamic appearance. However, these lightweight structures are typical components with multi-ribs. And because of their complex structures, lightweight structures that manufactured by traditional bending process are prone to producing various defects and have the poor geometric accuracy. Therefore, it is necessary to research the advanced bending forming process of lightweight structures. According to the analysis of specific lightweight structures, the forming processes of mechanical milling-filling roll bending of integral panel skin of aluminum alloys and warm tension-rotation bending of magnesium alloy profiles are proposed. By means of theoretical analysis, finite element numerical simulation and experiments, the filling roll bending process and warm tension-rotation bending process are researched. The main contents and results are as follows:
(1) The bending mechanics of the integral panel skins and profiles are studied. The forming principle of integral panel skin filling aided roll bending is analyzed systematically; the mechanical state, geometrical relationship and springback rule of rib and skin of integral panel skin with rib-inward and rib-outward are researched. The forming principle of warm tension-rotation bending of magnesium alloy is studied; the mechanical state and springback rule of different feature positions on the inside and outside of the profile are investigated. The theoretical analysis provides theoretical foundations for the mathematical model of bending process.
(2) The stress-strain curves are gained through uniaxial tensile tests. The three-dimensional elasto-plastic finite element model of aluminum alloy integral panel skin filling aided roll bending is established based on MSC.Marc package. The changes of stress and strain and springback law of integral panel skin during roll bending process are analyzed. The role of filler in bending process is revealed. The three-dimensional elasto-plastic thermo-mechanical coupled finite element model of magnesium alloy profile warm tension-rotation bending is established. The evolution rules of stress, strain, temperature, springback and geometric dimensions of the profile during warm tension-rotation bending process are sumarized.
(3) A roll bending equipment and data acquisition system for forming technical parameter are developed. The rubber and plastic filler are fabricated, and filling aided roll bending experiments are carried out in order to investigate the influence of filler and process parameters on surface quality and geometry accuracy of integral panel skins. The results indicate that the filler can meet the need of integral panel skins during roll bending process. Filler can change stress state of panel which generates uniform plastic deformation and improves the deformation harmonization between rib and skin. The radius of integral panel skin increases with increasing the top-roller reduction. When the reduction is small, the radius decreases sharply and the decrease amplitude is big. However, the decreasing trend becomes slower with the reduction increases. The empirical formula based on the Least Squares Regression shows the relationship between bending radius and reduction is the power exponential function.
(4) A tension-rotation bending equipment for magnesium alloy profiles is developed, and some warm tension-rotation bending experiments are conducted on it. The effects of forming temperature, bending angle and pre-tension amount on springback angle and geometric accuracy are analyzed. Moreover, the comparison between experimental results and simulation results is'conducted. Microstructure and microtexture of the profile are investigated by using an optical microscopy, X-rays diffraction and EBSD analysis system. The results show that the simulation results agree well with the experimental results. The effects of process parameters on springback and geometric dimension are coincident for both methods. Therefore, the simulation results can be used to conduct experiments. The evolution of microstructure and texture shows that during the warm tension-rotation bending process, a big number of twins emerge, which changes the initial orientations of grains, accommodates deformation of the c-axis and improves the plastic property of the profile.
(1)研究整体壁板和型材的弯曲成形机理。系统分析整体壁板填料辅助滚弯的成形原理,分析了筋条内置和外置两种整体壁板筋条和蒙皮的力学状态、几何关系和回弹规律；研究镁合金型材温热张力绕弯成形原理,分析了型材内外侧不同特征位置的力学状态和回弹规律；理论分析为弯曲成形数学模型的建立提供了理论依据。
(2)采用单向拉伸试验获得材料的应力应变关系,基于MSC.Marc建立了铝合金整体壁板填料辅助滚弯成形的三维弹塑性有限元模型,分析了滚弯成形过程中整体壁板的应力应变变化和回弹规律,揭示了填料在滚弯成形过程中的机理。基于MSC.Marc建立了镁合金型材温热张力绕弯成形的三维弹塑性热力耦合有限元模型,分析了绕弯成形过程中型材的应力应变、温度、回弹和几何尺寸的变化规律。
(3)研制滚弯成形装置,设计并开发了成形工艺参数的数据采集系统；自主研制橡胶和塑料填料,进行了填料辅助整体壁板的滚弯成形实验,研究了填料和工艺参数对整体壁板表面质量和几何精度的影响。结果表明：研制的填料满足了整体壁板滚弯成形的要求,填料改变了壁板的受力状态,使蒙皮产生均匀的塑性变形,提高了蒙皮和筋条的变形协调性。随着上辊压下量的增大,壁板弯曲半径减小。当压下量较小时,、随着压下量的增大,壁板弯曲半径急剧减小；当压下量较大时,随着压下量的增大,弯曲半径减小幅度降低；基于最小二乘法获得的经验公式表明,压下量与弯曲半径呈幂指数函数关系。
(4)研制镁合金型材温热张力绕弯成形装置,进行镁合金型材温热张力绕弯成形实验,分析成形温度、弯曲角度和预拉伸量对型材回弹角和几何精度的影响,将实验结果与模拟结果对比分析；采用光学显微镜、X射线衍射仪和EBSD技术系统分析型材的微观组织和织构演变。结果表明：模拟结果和实验结果基本吻合,工艺参数对回弹和几何尺寸变化的影响规律一致,模拟结果可以用于指导实验。微观组织和织构变化规律表明：温热弯曲成形过程中,大量孪晶出现,改变了晶粒的初始取向,协调了晶粒c轴的应变,提高了型材的塑性变形能力。
Lightweight is the long-term goal of aerospace, rail transport and other industries. As the typical lightweight structures, the integral panel skins of aluminum alloys and complex cross-section profile of magnesium alloys have been widely used in the launch vehicles, missiles, aircrafts and automobile traffic. These lightweight structures are often bent to appearance with certain curvature in order to acquire the overall structure of superior performance and improve the aerodynamic appearance. However, these lightweight structures are typical components with multi-ribs. And because of their complex structures, lightweight structures that manufactured by traditional bending process are prone to producing various defects and have the poor geometric accuracy. Therefore, it is necessary to research the advanced bending forming process of lightweight structures. According to the analysis of specific lightweight structures, the forming processes of mechanical milling-filling roll bending of integral panel skin of aluminum alloys and warm tension-rotation bending of magnesium alloy profiles are proposed. By means of theoretical analysis, finite element numerical simulation and experiments, the filling roll bending process and warm tension-rotation bending process are researched. The main contents and results are as follows:
(1) The bending mechanics of the integral panel skins and profiles are studied. The forming principle of integral panel skin filling aided roll bending is analyzed systematically; the mechanical state, geometrical relationship and springback rule of rib and skin of integral panel skin with rib-inward and rib-outward are researched. The forming principle of warm tension-rotation bending of magnesium alloy is studied; the mechanical state and springback rule of different feature positions on the inside and outside of the profile are investigated. The theoretical analysis provides theoretical foundations for the mathematical model of bending process.
(2) The stress-strain curves are gained through uniaxial tensile tests. The three-dimensional elasto-plastic finite element model of aluminum alloy integral panel skin filling aided roll bending is established based on MSC.Marc package. The changes of stress and strain and springback law of integral panel skin during roll bending process are analyzed. The role of filler in bending process is revealed. The three-dimensional elasto-plastic thermo-mechanical coupled finite element model of magnesium alloy profile warm tension-rotation bending is established. The evolution rules of stress, strain, temperature, springback and geometric dimensions of the profile during warm tension-rotation bending process are sumarized.
(3) A roll bending equipment and data acquisition system for forming technical parameter are developed. The rubber and plastic filler are fabricated, and filling aided roll bending experiments are carried out in order to investigate the influence of filler and process parameters on surface quality and geometry accuracy of integral panel skins. The results indicate that the filler can meet the need of integral panel skins during roll bending process. Filler can change stress state of panel which generates uniform plastic deformation and improves the deformation harmonization between rib and skin. The radius of integral panel skin increases with increasing the top-roller reduction. When the reduction is small, the radius decreases sharply and the decrease amplitude is big. However, the decreasing trend becomes slower with the reduction increases. The empirical formula based on the Least Squares Regression shows the relationship between bending radius and reduction is the power exponential function.
(4) A tension-rotation bending equipment for magnesium alloy profiles is developed, and some warm tension-rotation bending experiments are conducted on it. The effects of forming temperature, bending angle and pre-tension amount on springback angle and geometric accuracy are analyzed. Moreover, the comparison between experimental results and simulation results is'conducted. Microstructure and microtexture of the profile are investigated by using an optical microscopy, X-rays diffraction and EBSD analysis system. The results show that the simulation results agree well with the experimental results. The effects of process parameters on springback and geometric dimension are coincident for both methods. Therefore, the simulation results can be used to conduct experiments. The evolution of microstructure and texture shows that during the warm tension-rotation bending process, a big number of twins emerge, which changes the initial orientations of grains, accommodates deformation of the c-axis and improves the plastic property of the profile.
引文
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