多辊下压式柔性拉形过程及其数值模拟研究
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摘要
拉伸成形(简称拉形)具有成形精度高和回弹量小等优点,是飞机蒙皮的主要成形方式。蒙皮件是构成飞机外形的关键零件,其制造质量直接影响飞机的气动性能。随着航空工业的发展,国内外飞机的产量越来越大,质量要求越来越高,其研发周期却在迅速缩短。此外,新一代飞机普遍采用翼身融合体设计,需要大面积的S形、马鞍形等有凹有凸、有弯有扭的复杂形状蒙皮。这些都为拉形技术带来了崭新的挑战,拉形装备迫切需要提高自身的柔性以适应航空工业的发展。
多辊下压式拉形技术是一种基于新原理的柔性拉形技术,其基本原理是,用可浮动夹钳将板材两端夹住,采用离散为若干个的可摆头压辊下压板材悬空区的方式使板材贴模成形。该技术具有柔性高、成形范围大、板材贴模容易、成本低、控制简单、成形质量好等优点,具有较高的工程应用价值和学术研究价值。
本文的主要研究内容与结论如下:
1.在多辊下压式拉形装置及工艺研究方面分析了传统拉形机的结构特点,指出了传统拉形机存在的问题和多辊下压式拉形机的优势。给出了多辊下压式拉形实验装置设计方案,包括压辊机构、刚性浮动夹钳和柔性浮动夹钳两种夹钳机构、齿形压板和带筋压板两种夹钳压板;对多辊下压式拉形实验装置的可行性和实用性进行了实验验证。总结了多辊下压式拉形的典型成形工艺,即直接下压工艺、弯曲—下压工艺和上浮—下压工艺。研究了多辊下压式拉形中夹钳和压辊的加载控制方法。
2.在多辊下压式拉形有限元建模方法研究方面
基于ANSYS/LS-DYNA,建立了多辊下压式拉形的有限元分析模型和显—隐式回弹分析模型。通过对有限元模型的收敛性分析确定了较合理的板材单元尺寸。针对柔性浮动夹钳摆头的实际情况,提出了夹钳质心的修改方案并进行了验证,结果表明:该方案能够模拟出夹钳摆头的实际情况。对本文建立的有限元模型的可行性和准确性进行了实验验证,结果表明:数值模拟结果在形状特点、变形规律、回弹结果和危险点位置等方面与实验结果吻合较好。
3.在多辊下压式拉形工艺的数值模拟研究方面
根据多辊下压式拉形装置的结构特点和控制方式,推导了典型工艺过程中夹钳上浮量和压辊下压量的计算公式,并对压辊下压量公式进行了数值模拟和实验验证。以典型曲面为研究对象,对传统拉形和多辊下压式拉形过程进行了数值模拟,结果表明:与传统拉形相比,采用多辊下压式拉形时板材贴模更容易,成形件应力、应变、板厚分布更均匀。对比分析了三种典型工艺对成形结果的影响,总结了三种工艺各自的优缺点和适用范围;研究了板材和模具之间润滑对成形结果的影响,结果表明:良好的润滑能够使成形件应变、板厚分布更均匀。
4.在夹钳机构对成形结果的影响研究方面
对柔性浮动夹钳的夹持效果进行了仿真和实验验证,证明了柔性浮动夹钳能够较好的应用于多辊下压式拉形中,实现对板材的柔性、浮动夹持。对比分析了刚性浮动夹钳和柔性浮动夹钳对成形结果的影响,结果表明:采用柔性浮动夹钳时所得到的成形件应力、应变、板厚分布更均匀,且不容易产生起皱、拉裂等缺陷。对比分析了齿形压板和带筋压板两种夹钳压板对成形结果的影响,探讨了两种压板的优缺点和适用范围,并进行了相关实验验证;给出了带筋压板临界夹持阻力的计算方法,推导了相关理论计算公式。
5.在压辊机构对成形结果的影响研究方面
分析了滚动压辊和滑动压辊对成形结果的影响,探讨了压辊滚动设计的必要性和实用性;探讨了压辊机构离散化程度对成形结果的影响,确定了在本文研究条件下较优的压辊机构离散化程度;分析了两侧压辊到板材边缘的距离对成形结果的影响;系统探讨了压辊位置对成形结果的影响,首先对比分析了压辊位于模具上方和压辊位于悬空区上方时多辊下压式拉形过程和数值模拟结果,探讨了压辊在以上两种位置适合成形的工件类型;然后针对压辊位置在悬空区上方这种情况,分析了压辊与模具之间距离和压辊与夹钳之间距离对成形结果的影响,结果表明:压辊距离模具越近,压辊对板材施力方向越接近模具端面法线方向且成形件应变、板厚分布越均匀,而压辊与夹钳之间距离对成形结果影响不大。
6.在多辊下压式拉形过程中起皱缺陷的研究方面
由于拉形主要用于薄板件的成形,所以拉形过程中较易发生起皱缺陷。以鞍形面和球形面为研究对象,对工件起皱现象进行了模拟,结果表明鞍形面皱曲主要产生在板材中部,而球形面皱曲主要产生在板材两侧,采用壳单元主应变状态和应力应变顺序对应定律对产生皱曲的原因进行了解释,并从板材宏观受力的角度分析了起皱过程。以鞍形面为研究对象,对传统拉形和多辊下压式拉形起皱现象进行了模拟,结果表明:与传统拉形方式相比,多辊下压式拉形方式不易起皱。分析了板厚、板材与模具之间润滑和预拉对鞍形面中部起皱的影响规律,结果表明:板材厚度越薄,润滑越充分,预拉量越小,板材越容易起皱;提出了压辊分步下压的起皱抑制方法,分析了该方法能够抑制鞍形面中部起皱的原因,并采用数值模拟方法进行了验证。
Stretch forming process are extensively used for forming aircraft outer skin parts. The stretched parts will have better shape control and smaller springback after forming because of the metal strain-hardening. The skin parts are main parts for structuring aerodynamic configuration, so the forming quality of skin parts are directly influence the aerodynamic performance of aircrafts. As the rapid development of aviation industry, the demand of skin parts are increasing, the quality is becoming higher and higher and the development cycles are getting shorter and shorter. In addition, as the new generation of aircraft commonly use blended wing body design, the aircraft manufacturers require a lot of complex shaped skin parts, such as S-shaped, saddle-shaped parts. These all brings new challenges to the stretch forming technology and it is important to enhance the flexibility of stretch forming equipments to adapt the development of aviation industry.
Multi-roll stretch forming (MRSF) is a new flexible stretch forming technology based on a new principle. The basic principle of multi-roll stetch forming is clamping both ends of sheet metal with flexible floating clamp device firstly, and then using a number of discrete rollers press the free area of sheet metal to form the part. MRSF can improve the forming range of stretch forming and make the sheet metal attaching to the die easily. In addition, it also have other advantages, such as low cost, simple control and good quality. MRSF is provided with higher engineering applied value and academic research value.
The main contents and conclusions are as follows:
1. Researh on MRSF equipment and forming process
The structural characteristics of the traditional stretch forming machine is analyzed, and the shortcomings of traditional stretch forming machine and the advantages of MRSF are given. The design scheme of MRSF testing machine is discussed, including the structure of roller device, two types of clamp device (rigid floating clamp and flexible floating clamp)and two types of clamp plate (tooth-shape clamp plate and brake clamp plate; the related experimental validation is finished. The typical processes are summarized, which are directly press forming process, bend-press forming process and lift up-press forming process. The control methods of roller device and clamp device are studied.
2. Research on the finite element analysis (FEA) modeling method of MRSF
Based on the FEA software ANSYS/LS-DYNA, the FEA model and explicit-implicit springback analysis model are established. Using the numerical simulation method, the convergence of the FEA model is analyzed and the element size of sheet metal are determined. For the practical swing situation of the flexible floating clamp, a FEA model program to modify the clamp centroid is established; the simulation validation is finished, and the results indicate that the practical situation of clamp swing can be reflected in this program. the related experimental validation of finite element modeling accuracy is finished, the results indicate that the deformation, springback and dangerous point prediction results of simulation coincide with the experimental results.
3. Numerical simulation on MRSF process
According to the structural characteristics and control method of MRSF testing machine, the calculation formulas of the loading amount of clamp and roller in typical forming process are derived; the related numerical simulation and experimental validation are finished, the results indicate that the formula is feasible. Take the typical surface parts as research object, the processes of traditional stretch forming and MRSF are simulated, the numerical simulation results indicate that the parts formed by MRSF process, comparing with the traditional stretch forming process, have more uniform distributions of stress, strain and thickness. The three typical forming processes of MRSF are simulated, the using scope and effect on formed parts of different forming processes are analyzed. The lubrication effect between the sheet metal and die is studied, the results indicate that good lubrication can make the strain and thickness distributions of formed parts more uniform.
4. The effect of clamp device on the forming results
Numerical simulation and experimental validation of the clamping process of floating clamp device are done, the results proved that the clamp device can be applied to the MRSF process. The effect of rigid floating clamp (RFC) and flexible floating clamp (FFC) on forming results is comparative analyzed, the results shows that the stress, strain and thickness distributions of the parts formed by FFC are more uniform and more prone to wrinkle and rupture by using RFC. Take the tooth-shaped clamp plate and brake clamp plate as research object, the effect of different clamp plate on forming results is comparative analyzed, the advantages and disadvantages are investigated and the related experimental is done, the results indicate that the two types of clamp plate are all feasible. Finally, the calculation formulas of critical clamping resistance of brake clamp are derived.
5. The effect of roller device on the forming results
The effect of sliding roller and rolling roller on forming results are studied, the results indicate that it is necessary and practical to design a roller unit with a roller head which can roll around itself. The discretization effect of the roller device on forming results is analyzed, and the optimal discretization of roller device in this case is determined. The effect of the distance between roller and the plate edge is analyzed, and the distance ranges of typical parts are calculated. The effect of different positions of roller device on forming results is studied, the results indicate that it is more suitable to form a large deformation 3D-surface when the roller device is on the top of die; For the situation that roller device is on the top of the free area of sheet metal, the effect of the distance between roller device and die on forming results is investigated, the results shows that the smaller the distance is, the more easily the shape can be formed, and the better the quality of formed part can be; In addition, the effect of the distance between roller device and clamp device on the forming results is studied, the results shows that the distance has little impact on the quality of forming results.
6. Research on wrinkle defects in MRSF process
For stretch forming process is mainly used to form thin metal plate, so the formed parts is always have wrinkle defects. Take the saddle-shaped surface part and spherical surface part as research object again, the wrinkling is simulated. The simulation results indicate: for the, wrinkling is on the middle of saddle-shaped surface part and on the both side of the spherical surface part, and the reasons of wrinkling are explained by principal strain state of shell element and the law of stress-strain. The wrinkling distribution area, wrinkling process and the cause of wrinkling of saddle-shaped surface and spherical surface parts are analyzed. Take saddle-shaped surface as the research object, the wrinkling is simulated. The simulation results indicate that, compared with the MRSF process, the traditional stretch forming process is more prone to wrinkle. The influence of thickness, lubrication and pre-stretching displacement to the wrinkling is analyzed. The results indicate that the thinner the sheet metal is and the better the lubrication is, the less prone to wrinkle; The pre-stretching can suppress wrinkling and the bigger the pre-stretching displacement is, the less prone to wrinkle. The wrinkle suppression method called fractional steps pressing mode is advanced, the related numerical simulation validation is finished. The simulation results indicate that this method can suppress the generation of wrinkles.
多辊下压式拉形技术是一种基于新原理的柔性拉形技术,其基本原理是,用可浮动夹钳将板材两端夹住,采用离散为若干个的可摆头压辊下压板材悬空区的方式使板材贴模成形。该技术具有柔性高、成形范围大、板材贴模容易、成本低、控制简单、成形质量好等优点,具有较高的工程应用价值和学术研究价值。
本文的主要研究内容与结论如下:
1.在多辊下压式拉形装置及工艺研究方面分析了传统拉形机的结构特点,指出了传统拉形机存在的问题和多辊下压式拉形机的优势。给出了多辊下压式拉形实验装置设计方案,包括压辊机构、刚性浮动夹钳和柔性浮动夹钳两种夹钳机构、齿形压板和带筋压板两种夹钳压板;对多辊下压式拉形实验装置的可行性和实用性进行了实验验证。总结了多辊下压式拉形的典型成形工艺,即直接下压工艺、弯曲—下压工艺和上浮—下压工艺。研究了多辊下压式拉形中夹钳和压辊的加载控制方法。
2.在多辊下压式拉形有限元建模方法研究方面
基于ANSYS/LS-DYNA,建立了多辊下压式拉形的有限元分析模型和显—隐式回弹分析模型。通过对有限元模型的收敛性分析确定了较合理的板材单元尺寸。针对柔性浮动夹钳摆头的实际情况,提出了夹钳质心的修改方案并进行了验证,结果表明:该方案能够模拟出夹钳摆头的实际情况。对本文建立的有限元模型的可行性和准确性进行了实验验证,结果表明:数值模拟结果在形状特点、变形规律、回弹结果和危险点位置等方面与实验结果吻合较好。
3.在多辊下压式拉形工艺的数值模拟研究方面
根据多辊下压式拉形装置的结构特点和控制方式,推导了典型工艺过程中夹钳上浮量和压辊下压量的计算公式,并对压辊下压量公式进行了数值模拟和实验验证。以典型曲面为研究对象,对传统拉形和多辊下压式拉形过程进行了数值模拟,结果表明:与传统拉形相比,采用多辊下压式拉形时板材贴模更容易,成形件应力、应变、板厚分布更均匀。对比分析了三种典型工艺对成形结果的影响,总结了三种工艺各自的优缺点和适用范围;研究了板材和模具之间润滑对成形结果的影响,结果表明:良好的润滑能够使成形件应变、板厚分布更均匀。
4.在夹钳机构对成形结果的影响研究方面
对柔性浮动夹钳的夹持效果进行了仿真和实验验证,证明了柔性浮动夹钳能够较好的应用于多辊下压式拉形中,实现对板材的柔性、浮动夹持。对比分析了刚性浮动夹钳和柔性浮动夹钳对成形结果的影响,结果表明:采用柔性浮动夹钳时所得到的成形件应力、应变、板厚分布更均匀,且不容易产生起皱、拉裂等缺陷。对比分析了齿形压板和带筋压板两种夹钳压板对成形结果的影响,探讨了两种压板的优缺点和适用范围,并进行了相关实验验证;给出了带筋压板临界夹持阻力的计算方法,推导了相关理论计算公式。
5.在压辊机构对成形结果的影响研究方面
分析了滚动压辊和滑动压辊对成形结果的影响,探讨了压辊滚动设计的必要性和实用性;探讨了压辊机构离散化程度对成形结果的影响,确定了在本文研究条件下较优的压辊机构离散化程度;分析了两侧压辊到板材边缘的距离对成形结果的影响;系统探讨了压辊位置对成形结果的影响,首先对比分析了压辊位于模具上方和压辊位于悬空区上方时多辊下压式拉形过程和数值模拟结果,探讨了压辊在以上两种位置适合成形的工件类型;然后针对压辊位置在悬空区上方这种情况,分析了压辊与模具之间距离和压辊与夹钳之间距离对成形结果的影响,结果表明:压辊距离模具越近,压辊对板材施力方向越接近模具端面法线方向且成形件应变、板厚分布越均匀,而压辊与夹钳之间距离对成形结果影响不大。
6.在多辊下压式拉形过程中起皱缺陷的研究方面
由于拉形主要用于薄板件的成形,所以拉形过程中较易发生起皱缺陷。以鞍形面和球形面为研究对象,对工件起皱现象进行了模拟,结果表明鞍形面皱曲主要产生在板材中部,而球形面皱曲主要产生在板材两侧,采用壳单元主应变状态和应力应变顺序对应定律对产生皱曲的原因进行了解释,并从板材宏观受力的角度分析了起皱过程。以鞍形面为研究对象,对传统拉形和多辊下压式拉形起皱现象进行了模拟,结果表明:与传统拉形方式相比,多辊下压式拉形方式不易起皱。分析了板厚、板材与模具之间润滑和预拉对鞍形面中部起皱的影响规律,结果表明:板材厚度越薄,润滑越充分,预拉量越小,板材越容易起皱;提出了压辊分步下压的起皱抑制方法,分析了该方法能够抑制鞍形面中部起皱的原因,并采用数值模拟方法进行了验证。
Stretch forming process are extensively used for forming aircraft outer skin parts. The stretched parts will have better shape control and smaller springback after forming because of the metal strain-hardening. The skin parts are main parts for structuring aerodynamic configuration, so the forming quality of skin parts are directly influence the aerodynamic performance of aircrafts. As the rapid development of aviation industry, the demand of skin parts are increasing, the quality is becoming higher and higher and the development cycles are getting shorter and shorter. In addition, as the new generation of aircraft commonly use blended wing body design, the aircraft manufacturers require a lot of complex shaped skin parts, such as S-shaped, saddle-shaped parts. These all brings new challenges to the stretch forming technology and it is important to enhance the flexibility of stretch forming equipments to adapt the development of aviation industry.
Multi-roll stretch forming (MRSF) is a new flexible stretch forming technology based on a new principle. The basic principle of multi-roll stetch forming is clamping both ends of sheet metal with flexible floating clamp device firstly, and then using a number of discrete rollers press the free area of sheet metal to form the part. MRSF can improve the forming range of stretch forming and make the sheet metal attaching to the die easily. In addition, it also have other advantages, such as low cost, simple control and good quality. MRSF is provided with higher engineering applied value and academic research value.
The main contents and conclusions are as follows:
1. Researh on MRSF equipment and forming process
The structural characteristics of the traditional stretch forming machine is analyzed, and the shortcomings of traditional stretch forming machine and the advantages of MRSF are given. The design scheme of MRSF testing machine is discussed, including the structure of roller device, two types of clamp device (rigid floating clamp and flexible floating clamp)and two types of clamp plate (tooth-shape clamp plate and brake clamp plate; the related experimental validation is finished. The typical processes are summarized, which are directly press forming process, bend-press forming process and lift up-press forming process. The control methods of roller device and clamp device are studied.
2. Research on the finite element analysis (FEA) modeling method of MRSF
Based on the FEA software ANSYS/LS-DYNA, the FEA model and explicit-implicit springback analysis model are established. Using the numerical simulation method, the convergence of the FEA model is analyzed and the element size of sheet metal are determined. For the practical swing situation of the flexible floating clamp, a FEA model program to modify the clamp centroid is established; the simulation validation is finished, and the results indicate that the practical situation of clamp swing can be reflected in this program. the related experimental validation of finite element modeling accuracy is finished, the results indicate that the deformation, springback and dangerous point prediction results of simulation coincide with the experimental results.
3. Numerical simulation on MRSF process
According to the structural characteristics and control method of MRSF testing machine, the calculation formulas of the loading amount of clamp and roller in typical forming process are derived; the related numerical simulation and experimental validation are finished, the results indicate that the formula is feasible. Take the typical surface parts as research object, the processes of traditional stretch forming and MRSF are simulated, the numerical simulation results indicate that the parts formed by MRSF process, comparing with the traditional stretch forming process, have more uniform distributions of stress, strain and thickness. The three typical forming processes of MRSF are simulated, the using scope and effect on formed parts of different forming processes are analyzed. The lubrication effect between the sheet metal and die is studied, the results indicate that good lubrication can make the strain and thickness distributions of formed parts more uniform.
4. The effect of clamp device on the forming results
Numerical simulation and experimental validation of the clamping process of floating clamp device are done, the results proved that the clamp device can be applied to the MRSF process. The effect of rigid floating clamp (RFC) and flexible floating clamp (FFC) on forming results is comparative analyzed, the results shows that the stress, strain and thickness distributions of the parts formed by FFC are more uniform and more prone to wrinkle and rupture by using RFC. Take the tooth-shaped clamp plate and brake clamp plate as research object, the effect of different clamp plate on forming results is comparative analyzed, the advantages and disadvantages are investigated and the related experimental is done, the results indicate that the two types of clamp plate are all feasible. Finally, the calculation formulas of critical clamping resistance of brake clamp are derived.
5. The effect of roller device on the forming results
The effect of sliding roller and rolling roller on forming results are studied, the results indicate that it is necessary and practical to design a roller unit with a roller head which can roll around itself. The discretization effect of the roller device on forming results is analyzed, and the optimal discretization of roller device in this case is determined. The effect of the distance between roller and the plate edge is analyzed, and the distance ranges of typical parts are calculated. The effect of different positions of roller device on forming results is studied, the results indicate that it is more suitable to form a large deformation 3D-surface when the roller device is on the top of die; For the situation that roller device is on the top of the free area of sheet metal, the effect of the distance between roller device and die on forming results is investigated, the results shows that the smaller the distance is, the more easily the shape can be formed, and the better the quality of formed part can be; In addition, the effect of the distance between roller device and clamp device on the forming results is studied, the results shows that the distance has little impact on the quality of forming results.
6. Research on wrinkle defects in MRSF process
For stretch forming process is mainly used to form thin metal plate, so the formed parts is always have wrinkle defects. Take the saddle-shaped surface part and spherical surface part as research object again, the wrinkling is simulated. The simulation results indicate: for the, wrinkling is on the middle of saddle-shaped surface part and on the both side of the spherical surface part, and the reasons of wrinkling are explained by principal strain state of shell element and the law of stress-strain. The wrinkling distribution area, wrinkling process and the cause of wrinkling of saddle-shaped surface and spherical surface parts are analyzed. Take saddle-shaped surface as the research object, the wrinkling is simulated. The simulation results indicate that, compared with the MRSF process, the traditional stretch forming process is more prone to wrinkle. The influence of thickness, lubrication and pre-stretching displacement to the wrinkling is analyzed. The results indicate that the thinner the sheet metal is and the better the lubrication is, the less prone to wrinkle; The pre-stretching can suppress wrinkling and the bigger the pre-stretching displacement is, the less prone to wrinkle. The wrinkle suppression method called fractional steps pressing mode is advanced, the related numerical simulation validation is finished. The simulation results indicate that this method can suppress the generation of wrinkles.
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