机器人柔性翻边成形轨迹优化  

Trajectory optimization of robot-assisted flexible flanging

作　　者：程旋[1] 赵亦希[1] 尤舒曼 CHENG Xuan;ZHAO Yixi;YOU Shuman(Shanghai Key Laboratory of Digital Manufacture for Thin-Walled Structures,Shanghai Jiaotong University,Shanghai 200240,China;AECC Commercial Aircraft Engine Co.,Ltd,Shanghai 200241,China)

机构地区：[1]上海交通大学上海市复杂薄板结构数字化制造重点实验室,上海200240 [2]中国航发商用航空发动机有限责任公司,上海200241

出　　处：《航空学报》2023年第4期274-287,共14页Acta Aeronautica et Astronautica Sinica

基　　金：国家重点研发计划(2020YFA0711102);一院高校联合创新基金项目(CALT201809)。

摘　　要：单条边或多条边带弧度翻边钣金件,在航空航天中应用广泛。采用机器人柔性翻边成形技术可克服传统手工成形劳动强度大,效率低,产品质量一致性和可靠性难以保证等局限性,实现多品种、小批量翻边钣金件快速精确成形制造。然而,机器人柔性翻边成形技术属于轨迹控制的局部加载成形技术,在成形过程中易出现自由端塌陷及回弹等缺陷。针对此问题,以典型特征翻边件为研究对象,采用有限元仿真和实验相结合的方法,分析了柔性翻边成形过程中塌陷形成机理,进而系统开展机器人柔性翻边成形轨迹优化研究。研究结果表明:成形滚轮切入轨迹对翻边件自由端塌陷影响最大,应选择自由端预压方案,且切入点距自由端距离取值为20 mm时改善效果最好;采用优化后的成形滚轮切入切出轨迹进行柔性翻边成形实验,可获得自由端无塌陷、翻边开角误差小于0.5°及过渡圆角半径误差小于0.5 mm的翻边件。A certain edge or multiple edges with curved flanged sheet metal parts are widely used in aerospace.The use of robot-assisted flexible flanging technology can overcome the limitations of traditional manual forming such as high labor intensity,low efficiency,and difficulty in guaranteeing the consistency and reliability of product quality,and realize the rapid and accurate forming of multi-passes and small-patch flanged sheet metal parts.However,robotassisted flexible flanging technology is a trajectory-controlled local loading forming technology,which is prone to such defects as free end collapse and springback during the forming process.Combined finite element simulation with ex⁃periment,the mechanism of collapse formation in the flexible flanging process is analyzed;the robot flexible flanging trajectory optimization is then studied.The results of the study show that the rolling-in trajectory of the forming roller has the greatest influence on the free end collapse of the flanged part,and the best improvement effect is achieved when the free end pre-forming scheme is selected and the distance from the rolling-in point to the free end is 20 mm.Based on the optimized forming roller rolling-in and rolling-out trajectory,the flanged parts can be obtained without free end collapse,and the error of the flanging opening angle and the fillet radius is less than 0.5°and 0.5 mm,respectively.

关 键 词：机器人柔性翻边 翻边件 有限元仿真 轨迹优化 成形质量 

分 类 号：V261.28[航空宇航科学与技术—航空宇航制造工程]