大型机翼整体壁板系统化喷丸成形技术
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摘要
大型机翼整体壁板是现代大型飞机重要的大型承力整体结构件并且通常直接构成飞机的气动外形。喷丸成形是现代大型轻质高强铝合金整体壁板件成形制造的首选技术方法,但如何实现大型机翼整体壁板的精确喷丸成形一直是现代航空制造技术领域的一个难点问题。针对这一工程问题,本文采用系统化的方法,将影响大型机翼整体壁板喷丸成形精度的因素分解为壁板平面板坯误差、成形参数设计准确度、成形参数控制精度、环境因素。针对这些因素,采用基于变形位能最小的板坯优化设计来减小由板坯导致的成形误差;采用数据拟合、人工神经网络以及解析模型计算相结合的喷丸成形参数综合设计方法来提高喷丸参数设计的精度和效率;建立了板坯修正模型以修正环境温度、喷丸设备参数波动等因素对成形件形状和尺寸的影响;对于从喷丸设备上下线后仍存在的外形贴模误差,则采用手提喷丸机进行局部的渐进式校形喷丸至外形贴模。壁板喷丸成形的工程实践表明,本文所提出的系统化方法能够有效提高大型机翼整体壁板喷丸成形的精度和效率,并可满足工业生产的需求。
Large integral wing skin panels are important integral structures of modern large aircrafts.These panels usually constitute the aerodynamic shape of aircraft directly.Shot peening is generally the preferred process for the forming of modern large wing skin panels made of high strength aluminum alloy.It is,however,still a difficult issue to precisely shot peen form these large wing skin panels in modern aircraft manufacturing industry.In this paper,a systematic method is proposed for shot peen forming of large wing skin panels.The factors that may influence the precision of shot peen formed large wing skin panels are classified into error of plane panel,accuracy of designed process parameters,control accuracy of process parameters,and environmental factors.The plane panel is optimized by minimizing deformation potential energy to reduce the dimension error induced by plane panel.To increase their accuracy and efficiency,the peening parameters are comprehensively designed by a combination of methods of data fitting,artificial neural network,and analytical model.Correction formulae for plane panel are presented to account for the influence of environmental temperature and oscillation of peening parameters to the final shape and dimensions of the shot peened wing skin panel.Portable shot peening machine is used to locally and gradually correct the panel from peen forming line to its desired shape.Industrial practice on shot peen forming of wing skin panels shows that the systematic method presented in this paper can effectively improve the precision and efficiency of wing skin panel shot peen forming and fulfill the requirement of industrial production.
Large integral wing skin panels are important integral structures of modern large aircrafts.These panels usually constitute the aerodynamic shape of aircraft directly.Shot peening is generally the preferred process for the forming of modern large wing skin panels made of high strength aluminum alloy.It is,however,still a difficult issue to precisely shot peen form these large wing skin panels in modern aircraft manufacturing industry.In this paper,a systematic method is proposed for shot peen forming of large wing skin panels.The factors that may influence the precision of shot peen formed large wing skin panels are classified into error of plane panel,accuracy of designed process parameters,control accuracy of process parameters,and environmental factors.The plane panel is optimized by minimizing deformation potential energy to reduce the dimension error induced by plane panel.To increase their accuracy and efficiency,the peening parameters are comprehensively designed by a combination of methods of data fitting,artificial neural network,and analytical model.Correction formulae for plane panel are presented to account for the influence of environmental temperature and oscillation of peening parameters to the final shape and dimensions of the shot peened wing skin panel.Portable shot peening machine is used to locally and gradually correct the panel from peen forming line to its desired shape.Industrial practice on shot peen forming of wing skin panels shows that the systematic method presented in this paper can effectively improve the precision and efficiency of wing skin panel shot peen forming and fulfill the requirement of industrial production.
引文
[1]曾元松,黄遐.大型整体壁板成形技术[J].航空学报,2008,29(3):721-727.ZENG Y S,HUANG X.Forming technologies of large integral panel[J].Acta Aeronautica et Astronautica Sinica,2008,29(3):721-727(in Chinese).
[2]曾元松,尚建勤,许春林,等.ARJ21飞机大型超临界机翼整体壁板喷丸成形技术[J].航空制造技术,2007(3):38-41.ZENG Y S,SHANG J Q,XU C L,et al.Shot peen forming of ARJ21large integral wing skin panels with supercritical airfoil[J].Aeronautical Manufacturing Technology,2007(3):38-41(in Chinese).
[3]张贤杰,裴广勇,王俊彪.基于UG的飞机整体壁板类零件数字化展开[J].航空制造技术,2003(2):57-60.ZHANG X J,PEI G Y,WANG J B.Digital development of aircraft wing skin panel parts based on UG[J].Aeronautical Manufacturing Technology,2003(2):57-60(in Chinese).
[4]王炯,李东升,李小强.整体壁板蒙皮曲面几何展开方法研究[J].塑性工程学报,2006,13(6):57-60.WANG J,LI D S,LI X P.Research on geometric development method of integral panel skin surface[J].Journal of Plasticity Engineering,2006,13(6):57-60(in Chinese).
[5]张贤杰,王关峰,王俊彪.基于特征映射的超临界机翼整体壁板板坯快速建模技术研究[J].机械科学与技术,2006,25(10):1209-1211.ZHANG X J,WANG G F,WANG J B.Rapid modeling of supercritical airfoil integral wing skin plane panels with feature mapping methods[J].Mechanical Science and Technology,2006,25(10):1209-1211(in Chinese).
[6]王永军,陈龙辉,乔明杰,等.大型客机机翼壁板喷丸成形延展问题研究与分析[J].航空制造技术,2012,413(17):32-35.WANG Y J,CHEN L H,QIAO M J,et al.Study on elongation after shot-peen forming for wing skin panel of large aircraft[J].Aeronautical Manufacturing Technology,2012,413(17):32-35(in Chinese).
[7]彭艳敏,陈金平,杨亮,等.大型飞机整体壁板喷丸成形延展变形分析[J].航空制造技术,2017,528(9):97-100.PENG Y M,CHEN J P,YANG L,et al.Study on elongation after shot peen forming for integral panel of large aircraft[J].Aeronautical Manufacturing Technology,2017,528(9):97-100(in Chinese).
[8]CHAMPAIGNE J.Almen strip process control[J].The Shot Peener,1990,4(2):1-2.
[9]MIAO H Y,GARIPY A,LEVERS A,et al.Prediction of shot peen forming through direct finite element simulation[C]∥The 12th International Conference on Shot Peening(ICSP-12),2014:336-341.
[10]MIAO H Y,LAROSE S,PERRON C,et al.An analytical approach to relate shot peening parameters to Almen intensity[J].Surface&Coatings Technology,2010,205(7):2055-2066.
[11]HARBURN B,MILLER J C.Shot peen forming of compound contours:U.S.4329862[P].1982-05-18.
[12]MALEKI E,FARRAHI G H,SHERAFATNIA K.Application of artificial neural network to predict the effects of severe shot peening on properties of low carbon steel[C]∥Advanced Structured Materials,2016:45-60.
[13]ZHANG X J,WANG J B,WANG Y J,et al.Prediction of shot peen forming parameters of integral aircraft wing panels[C]∥Advances in Materials Manufacturing Science and Technology,2006:937-940.
[14]ZHANG X J,WANG T,WANG J B,et al.Analytical modeling of shot peen forming process using cross-sectional linear indentation coverage method[J].International Journal of Mechanical Sciences,2017,133:838-845.
[15]XIAO X D,TONG X,LIU Y,et al.Prediction of shot peen forming effects with single and repeated impacts[J].International Journal of Mechanical Sciences,2018,137:182-194.
[16]FAUCHEUX P A,GOSSELIN F P,VESQUE M L.Simulating shot peen forming with eigenstrains[J].Journal of Materials Processing Technology,2018,254:135-144.
[17]胡凯征,吴建军,王涛,等.基于温度场的喷丸成形数值模拟及参数优化[J].中国机械工程,2007,18(3):292-295.HU K Z,WU J J,WANG T,et al.Numerical simulation and parameter optimization for shot peen forming process based on temperature gradient[J].China Mechanical Engineering,2007,18(3):292-295(in Chinese).
[18]WU W,ZENG Y S,HUANG X,et al.Finite element method simulation of shot peening wing skin panel[J].Transactions of Nonferrous Metals Society of China,2005,15(2):443-446.
[19]康小明.有限元法在机翼整体壁板成形中的应用[J].中国机械工程,2002,13(2):50-52.KANG X M.The application of finite element method in the forming of aircraft wing skin panels[J].China Mechanical Engineering,2002,13(2):50-52(in Chinese).
[20]LEVERS A,PRIOR A.Finite element analysis of shot peening[J].Journal of Materials Processing Technology,1998,80-81(98):304-308.
[21]WANG M T,ZENG Y,HUANG X,et al.Research on deformation of 7050aluminum alloy panels with stiffeners by pre-stress shot peen forming[C]∥AIP Conference Proceedings,2016:1-7.
[22]WANG M T,ZENG Y S,BAI X P,et al.Deformation rule of 7150aluminum alloy thick plate by pre-stress shot peen forming[C]∥Advanced Materials Research,2014,1052:477-481.
[23]MIAO H Y,DEMERS D,LAROSE S,et al.Experimental study of shot peening and stress peen forming[J].Journal of Materials Processing Technology,2010,210(15):2089-2102.
[24]尚建勤.预应力对喷丸成形的影响[J].锻压技术,2000,25(1):42-43.SHANG J Q.Effect of pre-stress on peen-forming[J].Forging&Stamping Technology,2000,25(1):42-43(in Chinese).
[25]李国祥,机翼整体壁板的预应力喷丸成形[J].航空制造工程,1998(2):16-18.LI G X.Pre-stress shot peen forming of integral wing skin panels[J].Aeronautical Manufacturing Engineering,1998(2):16-18(in Chinese).
[26]俞汉清,陈金德.金属塑性成形原理[M].北京:机械工业出版社,2005:267-269.YU H Q,CHEN J D.Principles of plastic metal forming[M].Beijing:China Machine Press,2005:267-269(in Chinese).
[27]张贤杰,王俊彪,杨海成.基于单元变形能的复杂曲面优化展开算法研究[J].西北工业大学学报,2006,24(2):270-274.ZHANG X J,WANG J B,YANG H C.Optimal development of doubly curved surfaces based on element deformation energy[J].Journal of Northwestern Polytechnical U-niversity,2006,24(2):270-274(in Chinese).
[2]曾元松,尚建勤,许春林,等.ARJ21飞机大型超临界机翼整体壁板喷丸成形技术[J].航空制造技术,2007(3):38-41.ZENG Y S,SHANG J Q,XU C L,et al.Shot peen forming of ARJ21large integral wing skin panels with supercritical airfoil[J].Aeronautical Manufacturing Technology,2007(3):38-41(in Chinese).
[3]张贤杰,裴广勇,王俊彪.基于UG的飞机整体壁板类零件数字化展开[J].航空制造技术,2003(2):57-60.ZHANG X J,PEI G Y,WANG J B.Digital development of aircraft wing skin panel parts based on UG[J].Aeronautical Manufacturing Technology,2003(2):57-60(in Chinese).
[4]王炯,李东升,李小强.整体壁板蒙皮曲面几何展开方法研究[J].塑性工程学报,2006,13(6):57-60.WANG J,LI D S,LI X P.Research on geometric development method of integral panel skin surface[J].Journal of Plasticity Engineering,2006,13(6):57-60(in Chinese).
[5]张贤杰,王关峰,王俊彪.基于特征映射的超临界机翼整体壁板板坯快速建模技术研究[J].机械科学与技术,2006,25(10):1209-1211.ZHANG X J,WANG G F,WANG J B.Rapid modeling of supercritical airfoil integral wing skin plane panels with feature mapping methods[J].Mechanical Science and Technology,2006,25(10):1209-1211(in Chinese).
[6]王永军,陈龙辉,乔明杰,等.大型客机机翼壁板喷丸成形延展问题研究与分析[J].航空制造技术,2012,413(17):32-35.WANG Y J,CHEN L H,QIAO M J,et al.Study on elongation after shot-peen forming for wing skin panel of large aircraft[J].Aeronautical Manufacturing Technology,2012,413(17):32-35(in Chinese).
[7]彭艳敏,陈金平,杨亮,等.大型飞机整体壁板喷丸成形延展变形分析[J].航空制造技术,2017,528(9):97-100.PENG Y M,CHEN J P,YANG L,et al.Study on elongation after shot peen forming for integral panel of large aircraft[J].Aeronautical Manufacturing Technology,2017,528(9):97-100(in Chinese).
[8]CHAMPAIGNE J.Almen strip process control[J].The Shot Peener,1990,4(2):1-2.
[9]MIAO H Y,GARIPY A,LEVERS A,et al.Prediction of shot peen forming through direct finite element simulation[C]∥The 12th International Conference on Shot Peening(ICSP-12),2014:336-341.
[10]MIAO H Y,LAROSE S,PERRON C,et al.An analytical approach to relate shot peening parameters to Almen intensity[J].Surface&Coatings Technology,2010,205(7):2055-2066.
[11]HARBURN B,MILLER J C.Shot peen forming of compound contours:U.S.4329862[P].1982-05-18.
[12]MALEKI E,FARRAHI G H,SHERAFATNIA K.Application of artificial neural network to predict the effects of severe shot peening on properties of low carbon steel[C]∥Advanced Structured Materials,2016:45-60.
[13]ZHANG X J,WANG J B,WANG Y J,et al.Prediction of shot peen forming parameters of integral aircraft wing panels[C]∥Advances in Materials Manufacturing Science and Technology,2006:937-940.
[14]ZHANG X J,WANG T,WANG J B,et al.Analytical modeling of shot peen forming process using cross-sectional linear indentation coverage method[J].International Journal of Mechanical Sciences,2017,133:838-845.
[15]XIAO X D,TONG X,LIU Y,et al.Prediction of shot peen forming effects with single and repeated impacts[J].International Journal of Mechanical Sciences,2018,137:182-194.
[16]FAUCHEUX P A,GOSSELIN F P,VESQUE M L.Simulating shot peen forming with eigenstrains[J].Journal of Materials Processing Technology,2018,254:135-144.
[17]胡凯征,吴建军,王涛,等.基于温度场的喷丸成形数值模拟及参数优化[J].中国机械工程,2007,18(3):292-295.HU K Z,WU J J,WANG T,et al.Numerical simulation and parameter optimization for shot peen forming process based on temperature gradient[J].China Mechanical Engineering,2007,18(3):292-295(in Chinese).
[18]WU W,ZENG Y S,HUANG X,et al.Finite element method simulation of shot peening wing skin panel[J].Transactions of Nonferrous Metals Society of China,2005,15(2):443-446.
[19]康小明.有限元法在机翼整体壁板成形中的应用[J].中国机械工程,2002,13(2):50-52.KANG X M.The application of finite element method in the forming of aircraft wing skin panels[J].China Mechanical Engineering,2002,13(2):50-52(in Chinese).
[20]LEVERS A,PRIOR A.Finite element analysis of shot peening[J].Journal of Materials Processing Technology,1998,80-81(98):304-308.
[21]WANG M T,ZENG Y,HUANG X,et al.Research on deformation of 7050aluminum alloy panels with stiffeners by pre-stress shot peen forming[C]∥AIP Conference Proceedings,2016:1-7.
[22]WANG M T,ZENG Y S,BAI X P,et al.Deformation rule of 7150aluminum alloy thick plate by pre-stress shot peen forming[C]∥Advanced Materials Research,2014,1052:477-481.
[23]MIAO H Y,DEMERS D,LAROSE S,et al.Experimental study of shot peening and stress peen forming[J].Journal of Materials Processing Technology,2010,210(15):2089-2102.
[24]尚建勤.预应力对喷丸成形的影响[J].锻压技术,2000,25(1):42-43.SHANG J Q.Effect of pre-stress on peen-forming[J].Forging&Stamping Technology,2000,25(1):42-43(in Chinese).
[25]李国祥,机翼整体壁板的预应力喷丸成形[J].航空制造工程,1998(2):16-18.LI G X.Pre-stress shot peen forming of integral wing skin panels[J].Aeronautical Manufacturing Engineering,1998(2):16-18(in Chinese).
[26]俞汉清,陈金德.金属塑性成形原理[M].北京:机械工业出版社,2005:267-269.YU H Q,CHEN J D.Principles of plastic metal forming[M].Beijing:China Machine Press,2005:267-269(in Chinese).
[27]张贤杰,王俊彪,杨海成.基于单元变形能的复杂曲面优化展开算法研究[J].西北工业大学学报,2006,24(2):270-274.ZHANG X J,WANG J B,YANG H C.Optimal development of doubly curved surfaces based on element deformation energy[J].Journal of Northwestern Polytechnical U-niversity,2006,24(2):270-274(in Chinese).