纤维增强金属层板零件充液成形过程及工艺分析
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摘要
对某型号飞机外表面盒形件进行研究,应用有限元软件Abaqus/Explicit建立玻璃纤维增强铝合金层板充液成形的有限元模型,研究充液成形过程中液室压力以及压边力对成形结果的影响,并通过实验验证仿真结果的准确性;通过对成形后的零件进行真空固化处理,最终得到合格零件。研究结果表明:在该方盒形零件的充液成形过程中,当成形加载压边力为2.0 MN,液室压力为30 MPa时,可以成形出质量良好的零件;成形后真空固化处理工艺能有效校正零件翘曲等现象,提高零件强度和刚度。
The outer surface of a box-shaped part in a certain type of aircraft was studied, and the finite element model of glass fiber reinforced aluminum laminate hydroforming process was established by using Abaqus/Explicit software. The effect of blank holder force coupled with cavity pressure on the forming results was investigated during the hydroforming procedure, and its accuracy was verified by experiments. Then, the qualified part was finally obtained by vacuum solidification of the formed part. The results show that a qualified box-shaped part can be obtained when the blank holder force is 2.0 MN and the cavity pressure is 30 MPa. Also, the vacuum solidification process of the formed part can rectify the warping phenomenon and improve the strength and stiffness of the part.
The outer surface of a box-shaped part in a certain type of aircraft was studied, and the finite element model of glass fiber reinforced aluminum laminate hydroforming process was established by using Abaqus/Explicit software. The effect of blank holder force coupled with cavity pressure on the forming results was investigated during the hydroforming procedure, and its accuracy was verified by experiments. Then, the qualified part was finally obtained by vacuum solidification of the formed part. The results show that a qualified box-shaped part can be obtained when the blank holder force is 2.0 MN and the cavity pressure is 30 MPa. Also, the vacuum solidification process of the formed part can rectify the warping phenomenon and improve the strength and stiffness of the part.
引文
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[16]刘永强,冯震宙,唐长红,等.不同铺层角度GLARE层板复合材料的抗鸟撞性能[J].机械工程材料,2016,40(5):105-110.LIU Yongqiang,FENG Zhengzhou,TANG Changhong,et al.Bird-impact resistance of GLARE laminate composite with different ply angles[J].Materials for Mechanical Engineering,2016,40(5):105-110.
[17]WANG Yao,LANG Lihui.Investigation into the overlapping sheet hydraulic bulge and its formability[J].Journal of the Brazilian Society of Mechanical Sciences and Engineering,2016,38(6):1635-1645.
[18]AUKUSH P,SANAN H.Experimental and numerical investigation on the uniaxial tensile response and failure of fiber metal laminates[J].Composites Part B,2017,125(15):259-274.
[19]EHSAN S,LANG Lihui,LIU Shichen.An innovative approach to mass production of fiber metal laminate sheets[J].Materials and Manufacturing Processes,2018,33(5):552-563.
[20]LIU Shichen,LANG Lihui,EHSAN S.Investigation into the fiber orientation effect on the formability of GLARE materials in the stamp forming process[J].Applied Composites Material,2018,25(2):255-267.
[2]王世明,吴中庆,张振军,等.大飞机用Glare层板的性能综合评价研究[J].材料导报,2010,24(9):88-95.WANG Shiming,WU Zhongqing,ZHANG Zhenjun,et al.Research of Glare laminates performance comprehensive evaluation applied to large aircraft[J].Materials Review,2010,24(9):88-95.
[3]郎利辉,张文尚,刘康宁,等.液室压力对异形长法兰盒形件充液成形过程的影响[J].锻压技术,2016,41(9):41-45.LANG Lihui,ZHANG Wenshang,LIU Kangning,et al.Influence of cavity pressure on box-shaped part with special-shaped long flanges in hydroforming process[J].Forging&Stamping Technology,2016,41(9):41-45.
[4]LUKE M,PAUL C,WESLEY J,et al.Stamp forming of polypropylene based fiber metal laminates:the effect of process variables on formability[J].Journal of Material Processing Technology,2006,172(2):163-168.
[5]HOU M.Stamp forming of continuous glass fiber reinforced polypropylene[J].Composites Part A:Applied Science and Manufacturing,1997,28(8):695-702.
[6]LUKE M,PAUL C,WESLEY J,et al.The effect of process temperature on the formability of polypropylene based fiber-metal laminates[J].Composites:Part A,2005,36(8):1158-1166.
[7]KALYANASUNDARAM S,VENKATESAN S.Effect of process parameters during forming of self reinforced-PP based Fiber Metal Laminate[J].Composite Structures,2013,97:332-337.
[8]梁中全,薛元德,陈绍杰,等.GLARE层板的力学性能及其在A380客机上的应用[J].玻璃钢/复合材料,2005,2(4):49-50.LIANG Zhongquan,XUE Yuande,CHEN Shaojie,et al.Mechanical properties of GLARE laminates and its application in aircraft A380[J].Glass Reinforce Plastic/Composites,2005,2(4):49-50.
[9]黄世民.一种新型飞机结构材料--纤维增强铝合金胶接层板[J].上海金属:有色分册,1993,14(4):43-47.HUANG Shimin.A new aircraft structure material:fiber reinforced aluminum laminate[J].Shanghai Metal:Nonferrous Fascicule,1993,14(4):43-47.
[10]马宏毅.玻璃纤维-铝合金层板的制备和性能研究[D].北京:北京航空材料研究院,2006:78.MA Hongyi.Research on the preparation and property of glass fiber reinforced aluminum laminate[D].Beijing:Beijing Institute of Aeronautical Materials,2006:78.
[11]ZAFAR R,LANG Lihui,ZHANG Rongjing.Analysis of hydro-mechanical deep drawing and the effects of cavity pressure on quality of simultaneously formed three-layer Al alloy parts[J].The International Journal of Advanced Manufacturing Technology,2015,80(9/10/11/12):2117-2128.
[12]ZHANG Rongjing,LANG Lihui,ZAFAR R.Investigation into thinning and spring back of multilayer metal forming using hydro-mechanical deep drawing(HMDD)for lightweight parts[J].The International Journal of Advanced Manufacturing Technology,2016,82(5/6/7/8):817-826.
[13]曹子振.玻璃纤维增强铝合金(GLARE)层板连接性能研究[D].哈尔滨:哈尔滨工程大学,2013:63.CAO Zizhen.Investigation of glass reinforced aluminum(GLARE)laminates bolted joint[D].Harbin:Harbin Engineering University,2013:63.
[14]李华冠.玻璃纤维-铝锂合金超混杂复合层板的制备及性能研究[D].南京:南京航空航天大学材料科学与技术学院,2016:149.LI Huaguan.Preparation and properties of glass fiber/aluminumlithium super hybrid laminates[D].Nanjing:Nanjing University of Aeronautics and Astronautics.College of Material Science and Technology,2016:149.
[15]佟安时,谢里阳,白鑫,等.纤维金属层板的拉伸性能研究[J].东北大学学报(自科版),2017,38(12):1736-1740.TONG Anshi,XIE Liyang,BAI Xin,et al.Study on tensile property of fiber metal laminates[J].Journal of Northeastern University(Nature Science),2017,38(12):1736-1740.
[16]刘永强,冯震宙,唐长红,等.不同铺层角度GLARE层板复合材料的抗鸟撞性能[J].机械工程材料,2016,40(5):105-110.LIU Yongqiang,FENG Zhengzhou,TANG Changhong,et al.Bird-impact resistance of GLARE laminate composite with different ply angles[J].Materials for Mechanical Engineering,2016,40(5):105-110.
[17]WANG Yao,LANG Lihui.Investigation into the overlapping sheet hydraulic bulge and its formability[J].Journal of the Brazilian Society of Mechanical Sciences and Engineering,2016,38(6):1635-1645.
[18]AUKUSH P,SANAN H.Experimental and numerical investigation on the uniaxial tensile response and failure of fiber metal laminates[J].Composites Part B,2017,125(15):259-274.
[19]EHSAN S,LANG Lihui,LIU Shichen.An innovative approach to mass production of fiber metal laminate sheets[J].Materials and Manufacturing Processes,2018,33(5):552-563.
[20]LIU Shichen,LANG Lihui,EHSAN S.Investigation into the fiber orientation effect on the formability of GLARE materials in the stamp forming process[J].Applied Composites Material,2018,25(2):255-267.