高强筋壁板压弯-蠕变复合成形技术研究:本构建模与仿真  

Research on bending−creep composite forming technology of panel with high strength ribs:constitutive modeling and simulation

作　　者：徐凌志 宋莹 刘春辉 徐永谦 湛利华[2,3,4] 杨有良[2,3,4] 童璨瑜 黄明辉 XU Lingzhi;SONG Ying;LIU Chunhui;XU Yongqian;ZHAN Lihua;YANG Youliang;TONG Canyu;HUANG Minghui(AVIC General Huanan Aircraft Industry Co.Ltd.,Zhuhai 519042,China;School of Mechanical and Electrical Engineering,Central South University,Changsha 410083,China;State Key Laboratory of Precision Manufacturing for Extreme Service Performance,Central South University,Changsha 410083,China;Light Alloy Research Institute,Central South University,Changsha 410083,China)

机构地区：[1]中航通飞华南飞机工业有限公司,广东珠海519042 [2]中南大学机电工程学院,湖南长沙410083 [3]中南大学极端服役性能精确制造全国重点实验室,湖南长沙410083 [4]中南大学轻合金研究院,湖南长沙410083

出　　处：《中南大学学报（自然科学版）》2023年第10期3895-3906,共12页Journal of Central South University:Science and Technology

基　　金：国家重点研发计划项目(2021YFB3400903);国家自然科学基金资助项目(51905551,52005516,52205435);高性能复杂制造国家重点实验室自主研究项目(ZZJKT2019-11,ZZJKT2021-03,ZZYJKT2022-07)。

摘　　要：针对带有高强筋等局部强刚度结构的整体壁板成形难的问题,结合塑性成形和蠕变成形技术,提出一种“压弯-蠕变”复合成形技术。通过蠕变时效和拉伸力学性能测试研究预先塑性变形对7B04-T7451铝合金蠕变时效行为的影响规律。通过引入位错密度微观变量,建立考虑塑性变形影响的蠕变本构模型,并通过用户子程序嵌入有限元分析软件MSC.MARC,实现“压弯-蠕变”复合成形过程仿真中不同工序间的塑性变形耦合计算。通过含高强筋的壁板构件成形模拟仿真,以及与无预压弯工序的蠕变成形及仿真结果进行对比。研究结果表明:塑性变形为3%可以提高铝合金的蠕变量1倍以上,但对力学性能影响不大;复合成形技术中压弯工序先使高强筋结构预成形,随后通过蠕变工序使壁板整体达到所需求的目标半径,仿真的构件成形型面半径与目标型面半径相比最大误差小于0.5 mm;仅通过蠕变工艺难以获得高强筋成形所需的变形量。A combined forming technology of bending forming and creep forming was proposed as"bending−creep"composite forming process to form the integral panels with strong stiffness structures such as high-ribs.The effect of pre-plastic-deformation of creep strain and mechanical properties of 7B04-T7451 aluminum alloy were studied by creep aging test and tensile test.By introducing relative dislocation density,the creep constitutive equation of 7B04-T7451 aluminum alloy considering pre-plastic-deformation effect was established to realize the coupling calculation of plastic deformation between different processes in the"bending−creep"forming simulation based on the user subroutine of finite element model MSC.MARC The results show that 3%pre-plastic-deformation can increase the creep strain by more than 1 times,but has little effect on the mechanical properties.The"bending−creep"forming simulation results of panel with high-ribs show that the high strength ribs are firstly pre-formed in bending process,and the whole panel is formed as final target shapes in the subsequent creep process.The maximum radius deviation between the simulation results and target shape is measured to be 0.4 mm.The simulation of creep forming process without pre-bending-process proves that the creep strain alone is insufficient to achieve the deformation required for the forming of high-ribs panel.

关 键 词：铝合金 塑性成形 蠕变成形 本构方程 有限元仿真 

分 类 号：TG146.2[一般工业技术—材料科学与工程]