航空整体结构件数控加工变形校正理论和方法研究
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摘要
变形校正是包括航空整体结构件制造在内的许多工业产、成品制造的关键工艺过程。目前,航空整体结构件的变形校正仍停留在凭操作者经验进行粗放生产的水平,因变形复杂无法校正或因操作不当引起工件报废的现象时有发生,严重影响航空整体结构件的生产效率和最终产品精度,并进一步影响航空航天产品的生产进度与生产成本。本文通过理论分析、有限元数值计算以及试验研究相结合的方法,对航空整体结构件变形校正理论和方法及相关关键技术进行了研究。全文共分七章。
第一章阐述了变形校正的基本概念、,在总结不同生产对象,国内外所采用变形校正理论和方法的基础上,针对航空整体结构件的结构特点与变形特点,提出了航空整体结构件变形校正的基本要求及需要研究解决的关键工艺理论和方法。最后给出了本学位论文的选题背景、主要研究内容和章节安排。
第二章在确定弯曲变形类型识别和变形量测量方法的基础上,首先研究了弯曲变形零件校正需要满足的基本曲率关系;进一步利用弹塑性理论,建立了弯曲变形零件校正需要满足的弯矩—反弯校正曲率间的通用关系式。针对所研究的航空整体结构件的主要截面特征为U型截面的结构特点,建立了U型截面工件弯曲变形校正的数学模型。为了生产操作方便,对于给定初始变形量和变形曲率的工件,给出了校正时压力机压头压下位移量的计算公式。为了验证所建立的数学模型,采用有限元方法对同一问题进行计算,理论值与有限元数值计算结果吻合得很好。
第三章针对复杂结构零件,无法用解析表达式求得校正参数的工程难题,提出了采用二分法、基于有限元技术进行变形校正参数计算的方法。设计隔框比例件的三点压弯试验,验证有限元模型的正确性。通过大量有限元数值计算,获得了典型隔框零件弯曲变形校正的规律曲线,用于指导校形生产。对多弯曲点的变形零件,提出了考虑整体校正精度的分段校正方法。
第四章给出了替代法快速建立扭转变形校正有限元模型的方法。在研究扭转变形校正基本理论的基础上,采用有限元技术,对隔框类零件扭转变形校正时各位移分量之间的量值关系进行了研究。通过大量有限元分析计算,对典型隔框零件扭转变形校正规律进行了研究。本章还对弯扭组合变形的校正理论和方法进行了研究。
第五章建立了毛坯初始残余应力引起工件加工变形的预测模型。对残余应力引起结构复杂的隔框零件变形进行了有限元计算,并进行了试验验证,有限元计算结果与试验值吻合得很好。首次对残余应力对变形校正参数计算精度的影响进行了研究。为校正参数的精确计算提供了技术支持。
第六章提出了U性截面工件安全校正极限参数的计算理论,给出了相应极限参数
Distortion correcting is a key process in semi and finished product manufacturing. It is also necessary in aeronautical monolithic component fabricating. At present, distortion correcting of aeronautical monolithic component basically remains at a lower level, which mainly depends on workers' experiences. Because of the complication of distortion and improper correcting operation, fail to meet the requirement of correction often occurs in the workshop of prototype airplane manufacturing. That ineluctably leads to the distorted components discarded as useless. This state of affairs reduces the productivity and lowers the precision of the finished products. Furthermore, production schedule and manufacturing costs of aeronautical product are influenced. In this dissertation, by coalescing theory analysis, finite element calculation and experiment, theory and method for correcting distorted aeronautical monolithic component are studied. Correlated key technologies are also researched. Seven chapters are included in this dissertation.Fundamental concept of distortion correcting is expounded firstly in chapter 1. Then, correcting theory and method with regard to different type of products and structures are summarized. According to the distortion characteristics of aeronautical monolithic components, some key correcting theories and methods are put forward. After that, background and significance of this research is pointed out. Finally, the main contents of this dissertation are summarized.In chapter 2, methods, to distinguish distortion type, to measure distortion value, are presented. Based on the methods, the relationship of several kinds of curvatures that a distorted part must be satisfied during its straightening process is studied. And then, by employing elastoplastic theory, a general expression between bending moment and reverse bending curvature is established when correcting bended distorted part. Considering most aeronautical monolithic components are U-section structure, a new mathematic model for correcting U-section bended part is founded. For operating convenience, a formula is obtained, and it is used to calculate the stroke of pressing down for straightening manufacturing distortion, while the original distortion value and curvature is given. To verify the mathematic model, finite element method is adopted to solve the same problem. The theoretical solution agrees well with the finite element result.For the complicated part, it is almost impossible to calculate correcting parameters by
第一章阐述了变形校正的基本概念、,在总结不同生产对象,国内外所采用变形校正理论和方法的基础上,针对航空整体结构件的结构特点与变形特点,提出了航空整体结构件变形校正的基本要求及需要研究解决的关键工艺理论和方法。最后给出了本学位论文的选题背景、主要研究内容和章节安排。
第二章在确定弯曲变形类型识别和变形量测量方法的基础上,首先研究了弯曲变形零件校正需要满足的基本曲率关系;进一步利用弹塑性理论,建立了弯曲变形零件校正需要满足的弯矩—反弯校正曲率间的通用关系式。针对所研究的航空整体结构件的主要截面特征为U型截面的结构特点,建立了U型截面工件弯曲变形校正的数学模型。为了生产操作方便,对于给定初始变形量和变形曲率的工件,给出了校正时压力机压头压下位移量的计算公式。为了验证所建立的数学模型,采用有限元方法对同一问题进行计算,理论值与有限元数值计算结果吻合得很好。
第三章针对复杂结构零件,无法用解析表达式求得校正参数的工程难题,提出了采用二分法、基于有限元技术进行变形校正参数计算的方法。设计隔框比例件的三点压弯试验,验证有限元模型的正确性。通过大量有限元数值计算,获得了典型隔框零件弯曲变形校正的规律曲线,用于指导校形生产。对多弯曲点的变形零件,提出了考虑整体校正精度的分段校正方法。
第四章给出了替代法快速建立扭转变形校正有限元模型的方法。在研究扭转变形校正基本理论的基础上,采用有限元技术,对隔框类零件扭转变形校正时各位移分量之间的量值关系进行了研究。通过大量有限元分析计算,对典型隔框零件扭转变形校正规律进行了研究。本章还对弯扭组合变形的校正理论和方法进行了研究。
第五章建立了毛坯初始残余应力引起工件加工变形的预测模型。对残余应力引起结构复杂的隔框零件变形进行了有限元计算,并进行了试验验证,有限元计算结果与试验值吻合得很好。首次对残余应力对变形校正参数计算精度的影响进行了研究。为校正参数的精确计算提供了技术支持。
第六章提出了U性截面工件安全校正极限参数的计算理论,给出了相应极限参数
Distortion correcting is a key process in semi and finished product manufacturing. It is also necessary in aeronautical monolithic component fabricating. At present, distortion correcting of aeronautical monolithic component basically remains at a lower level, which mainly depends on workers' experiences. Because of the complication of distortion and improper correcting operation, fail to meet the requirement of correction often occurs in the workshop of prototype airplane manufacturing. That ineluctably leads to the distorted components discarded as useless. This state of affairs reduces the productivity and lowers the precision of the finished products. Furthermore, production schedule and manufacturing costs of aeronautical product are influenced. In this dissertation, by coalescing theory analysis, finite element calculation and experiment, theory and method for correcting distorted aeronautical monolithic component are studied. Correlated key technologies are also researched. Seven chapters are included in this dissertation.Fundamental concept of distortion correcting is expounded firstly in chapter 1. Then, correcting theory and method with regard to different type of products and structures are summarized. According to the distortion characteristics of aeronautical monolithic components, some key correcting theories and methods are put forward. After that, background and significance of this research is pointed out. Finally, the main contents of this dissertation are summarized.In chapter 2, methods, to distinguish distortion type, to measure distortion value, are presented. Based on the methods, the relationship of several kinds of curvatures that a distorted part must be satisfied during its straightening process is studied. And then, by employing elastoplastic theory, a general expression between bending moment and reverse bending curvature is established when correcting bended distorted part. Considering most aeronautical monolithic components are U-section structure, a new mathematic model for correcting U-section bended part is founded. For operating convenience, a formula is obtained, and it is used to calculate the stroke of pressing down for straightening manufacturing distortion, while the original distortion value and curvature is given. To verify the mathematic model, finite element method is adopted to solve the same problem. The theoretical solution agrees well with the finite element result.For the complicated part, it is almost impossible to calculate correcting parameters by
引文
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