CN109092944B - Method for accurately forming large-scale complex curvature component - Google Patents
Method for accurately forming large-scale complex curvature component Download PDFInfo
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- CN109092944B CN109092944B CN201810858666.9A CN201810858666A CN109092944B CN 109092944 B CN109092944 B CN 109092944B CN 201810858666 A CN201810858666 A CN 201810858666A CN 109092944 B CN109092944 B CN 109092944B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D5/00—Bending sheet metal along straight lines, e.g. to form simple curves
- B21D5/14—Bending sheet metal along straight lines, e.g. to form simple curves by passing between rollers
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
- C21D1/773—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material under reduced pressure or vacuum
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
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Abstract
The invention belongs to the technical field of metal plate manufacturing, and relates to a method for accurately forming a large complex curvature component, which comprises the following steps: 1) performing roll bending treatment on an original plate of a large-scale complex curvature component to be processed based on the shape-following variable curvature of the molded surface of the mold; 2) and (4) carrying out creep age forming on the original plate subjected to the rolling treatment to obtain the large complex curvature component formed with high precision. The invention provides the accurate forming method of the large complex curvature component, which has the advantages of simple creep age forming operation, capability of avoiding the vacuum bag cracking phenomenon in the forming process and capability of eliminating the potential safety hazard of hurting people caused by component rebound.
Description
Technical Field
The invention belongs to the technical field of metal plate manufacturing, relates to a method for accurately forming a large-scale complex curvature component, and particularly relates to a method for manufacturing a complex curvature component for aerospace through variable curvature roll bending-creep age forming.
Background
Creep age forming is a novel sheet metal forming method developed for realizing accurate forming and high-performance forming collaborative manufacturing of large-scale integral high-strength aluminum alloy components for aerospace, and has the advantages of high forming accuracy, low cost, high repetition rate, low residual stress and the like. The technology is mainly applied to the forming and manufacturing of low-curvature components, such as upper and lower skins of an airplane wing. For creep age forming manufacturing of a complex large-curvature member, the problem that the chord height between the member and the mold surface is too large, which causes great difficulty in actual vacuum bag sealing operation is faced, as shown in fig. 1. The large component with complex curvature for aerospace use usually has certain strength and rigidity due to design requirements, the component can be bent to approach the mold surface only by continuously vacuumizing and loading, and in the process, a vacuum bag is sucked into a cavity formed by the component and the mold, so that the component is easy to break due to uneven stress or is finally crushed by the component, and the component fails to form; and after the vacuum bag is broken, the component rebounds, so that people are easily injured, and safety accidents occur.
Disclosure of Invention
In order to solve the technical problems in the prior art, the invention provides the accurate forming method of the large complex curvature component, which has the advantages of simple creep age forming operation, capability of avoiding the vacuum bag cracking phenomenon in the forming process and capability of eliminating the potential safety hazard of hurting people caused by component rebound.
In order to achieve the purpose, the invention adopts the following technical scheme:
a method for accurately forming a large-scale complex curvature component is characterized by comprising the following steps: the method for accurately forming the large complex curvature member comprises the following steps of:
1) performing roll bending treatment on an original plate of a large-scale complex curvature component to be processed based on the shape-following variable curvature of the molded surface of the mold;
2) and (4) carrying out creep age forming on the original plate subjected to the rolling treatment to obtain the large complex curvature component formed with high precision.
Preferably, the specific implementation manner of step 1) adopted by the invention is as follows:
1.1) extracting a central symmetrical curve L1 of the molded surface of the mold, and amplifying the central symmetrical curve L1 by m times to obtain a curve L2, wherein m is more than 1;
1.2) cutting a curve L3 from a curve L2, wherein the length of the curve L3 is the same as that of a large complex curvature component to be machined and molded, the curvature change of the curve L3 is consistent with the mold surface, and the curvature radius of the curve L3 is larger than that of the mold surface;
1.3) according to the structure and deformation characteristics of the large complex curvature member to be processed and formed, optimizing a curve L3 to obtain a curve L4, wherein the curve L4 is a side contour line of the large complex curvature member to be processed and formed after roll bending;
1.4) dividing the curve L4 into n sections, wherein n is 2-10, the curvature of each section of the curve in the n sections is regarded as equal curvature, and the curvature radius of each section of the curve in the n sections is the curvature radius at the left (right) end point;
1.5) measuring the radius of curvature r of the left (right) end point of each curve in the curve L4iObtaining the roll bending upper roll pressing quantity d of each section of the curve according to finite element simulation calculationi1, 2 …. n;
1.6) obtaining the upper roll pressing amount d according to calculationiAnd performing sectional roll bending on the component.
Preferably, the specific implementation manner of step 2) adopted by the invention is as follows:
2.1) carrying out vacuum bag sealing on the roll-bent raw plate of the large complex curvature component;
2.2) after the vacuum bag is sealed, putting the whole of the original plate and the mould of the large-scale complex curvature component into an autoclave for vacuumizing, heating and boosting;
2.3) preserving heat and pressure for 5-25h, and generating creep deformation in the large complex curvature component to be processed; and (3) cooling and pressure relief are carried out after the experiment, and the component is taken out when the temperature is reduced to 50-60 ℃, so that the large complex curvature component formed with high precision is finally obtained.
The invention has the advantages that:
the invention provides a method for accurately forming a large-scale complex curvature component, which comprises the steps of carrying out roll bending treatment on a raw plate of the large-scale complex curvature component to be processed based on the shape-following variable curvature of a mold profile; and (4) carrying out creep age forming on the original plate subjected to the rolling treatment to obtain the large complex curvature component formed with high precision. In order to solve the problem that creep aging forming of large complex curvature components is difficult to operate due to high chord, the components are rolled and bent firstly to reduce the chord height. The small end of the complex curvature ellipsoidal component has small curvature radius and small deformation, and the large end has small curvature radius and large deformation. If the member is subjected to single-curvature roll bending, the whole area of the member can generate plastic deformation; compared with the simple creep age forming, the plastic deformation amount of the small end of the component is increased, so that the small end can be over-bent. Therefore, the member is subjected to the shape-following variable-curvature roll bending strategy based on the mold surface, namely, the variable-curvature roll bending of the member is designed according to the curvature of the central symmetrical curve of the mold surface, so that the bending radius of the small end of the member is large, the over-bending deformation is reduced, and the precision is improved; the large-end roll bending curvature radius is small, the deformation is increased, the operation feasibility is increased, and the precision is improved. The invention provides a method for roll bending and creep aging forming of a complex large-curvature and large-size component, and the method reduces the chord height, simplifies the creep aging forming operation and avoids the vacuum bag cracking phenomenon in the forming process; meanwhile, the potential safety hazard of hurting people caused by the rebounding of the components is eliminated. According to the deformation characteristics of the component, the component is relatively subjected to the roll bending with the variable curvature based on the profile of the die and the roll bending with the single curvature, and the shape precision obtained after creep aging composite forming is higher. The invention reduces the chord height after the component is rolled and bent, reduces the outline dimension of the die, and reduces the processing and manufacturing cost of the die and the use cost of the autoclave.
Drawings
FIG. 1 is a schematic view of the chordal height between a component and a mold surface in the prior art;
FIG. 2 is a schematic flow chart of a method for precisely forming a large complex-curvature member according to the present invention;
FIG. 3 is a schematic representation of a mold profile centrosymmetric curve L1 and a corresponding magnified curve L2;
FIG. 4 is a schematic view taken on curve L2 at curve L3;
FIG. 5 is a schematic illustration of curve L4 optimized for curve L3;
FIG. 6 is a schematic view of the radius of curvature of each end point measured on curve L4;
fig. 7 is a schematic view of the roll-bent component.
Detailed Description
The theoretical basis of the invention is as follows: according to the deformation characteristics of the component, the component is relatively subjected to single-curvature roll bending based on the shape-following variable-curvature roll bending of the molded surface of the die, and the shape precision obtained after creep aging composite forming is higher. A variable curvature roll bending-creep aging composite accurate forming method for a large complex curvature component. On one hand, the chord height of the component and the molded surface of the die is reduced after the roll bending, so that the operation is simple; on the other hand, the profile precision of the member obtained by the die-profile-following variable-curvature roll bending-creep age forming is higher than that obtained by the single-curvature roll bending-creep age forming.
The member has the characteristics of large size, complex appearance and the like. The size of the component is between 0.5m and 10m, and can be even larger, the chord height between the component and the molded surface of the mold is larger along with the increase of the size, the processes of pasting high-temperature glue, sealing a vacuum bag and the like in actual forming are more difficult, and the failure possibility is also higher; the outer surface of the component has complex curvature, such as ellipsoid and spherical, and the shape of the component is more difficult to form accurately under large size. In order to solve the problem that the creep aging forming of the large chord height of a large complex curvature component is difficult to operate, the component is rolled and bent firstly to reduce the chord height. The small end of the complex curvature ellipsoidal component has small curvature radius and small deformation, and the large end has small curvature radius and large deformation. If the member is subjected to single-curvature roll bending, the whole area of the member can generate plastic deformation; compared with the simple creep age forming, the plastic deformation amount of the small end of the component is increased, so that the small end can be over-bent. Therefore, the member is subjected to the shape-following variable-curvature roll bending strategy based on the mold surface, namely, the variable-curvature roll bending of the member is designed according to the curvature of the central symmetrical curve of the mold surface, so that the bending radius of the small end of the member is large, the over-bending deformation is reduced, and the precision is improved; the large-end roll bending curvature radius is small, the deformation is increased, the operation feasibility is increased, and the precision is improved.
The invention provides a variable curvature roll bending-creep aging composite accurate forming method of a large complex curvature component, which comprises the following basic processes (a flow schematic diagram is shown as 2):
1) the member is based on the following variable curvature roll bending design of the mould profile:
1.1) extracting a central symmetry curve L1 of the mold surface, and magnifying the central symmetry curve L1 by m (times more than 1) to obtain a curve L2, as shown in FIG. 3;
1.2) cutting out a curve L3 from an enlarged curve L2, wherein the length of the curve L3 is the length of a member, the curvature change rule of the curve L3 is consistent with the mold surface, and the curvature radius is larger than the curvature radius of the mold surface, as shown in FIG. 4;
1.3) according to the structure and deformation characteristics of the member, optimizing a curve L3 to obtain a curve L4, wherein the curve L4 is a side contour line of the member after roll bending. Optimization examples are as follows: if the member deforms a little, the curvature radius of the small end portion of the curve L3 can be increased, even to a straight line, as shown in fig. 5.
1.4) dividing the curve L4 into n sections, wherein the number n of the sections is generally between 2 and 10, each section of curve is regarded as equal curvature, and the curvature radius is the curvature radius at the left (right) end point, as shown in FIG. 6;
1.5) measuring the radius of curvature r of the left (right) end point of each curve in the curve L4i(i is 1, 2 …. n), and then calculating the roll bending upper roll pressing amount d of each section of the curve according to finite element simulationi(i＝1，2….n)；
1.6) obtaining the upper roll pressing amount d according to calculationiThe member is roll-bent in sections as shown in fig. 7.
2) And creep age forming is carried out after the member is subjected to variable curvature bending along with the shape rolling. The height of the chord of the rolled and bent component is high and low, and the vacuum bag is easy to seal. After the vacuum bag is sealed, the whole component and the die enter an autoclave for vacuumizing, heating and boosting; then preserving heat and maintaining pressure for a certain time (5-25 hours), and generating creep deformation inside the component; and (4) cooling and relieving pressure after the experiment, and taking out the component when the temperature is reduced to 50-60 ℃ to finally obtain the high-precision formed component.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (3)
1. A method for accurately forming a large-scale complex curvature component is characterized by comprising the following steps: the method for accurately forming the large complex curvature member comprises the following steps of:
1) the method is characterized in that roll bending treatment is carried out on an original plate of a large complex curvature component to be processed based on the shape-following variable curvature of a mold profile, and specifically comprises the following steps: designing variable-curvature roll bending of the member according to the curvature of the centrosymmetric curve of the molded surface of the die, so that the roll bending curvature radius of the small end of the member is reduced, the over-bending deformation is caused, and the roll bending curvature radius of the large end is reduced, and the deformation is caused;
2) and (3) carrying out creep age forming on the original plate subjected to the roll bending treatment to obtain the large complex curvature component formed with high precision.
2. The method for accurately forming a large-scale complex curvature member according to claim 1, wherein: the specific implementation manner of the step 1) is as follows:
1.1) extracting a central symmetrical curve L1 of the molded surface of the mold, and amplifying the central symmetrical curve L1 by m times to obtain a curve L2, wherein m is more than 1;
1.2) cutting a curve L3 from a curve L2, wherein the length of the curve L3 is the same as that of a large complex curvature component to be machined and molded, the curvature change of the curve L3 is consistent with the mold surface, and the curvature radius of the curve L3 is larger than that of the mold surface;
1.3) according to the structure and deformation characteristics of the large complex curvature member to be processed and formed, optimizing a curve L3 to obtain a curve L4, wherein the curve L4 is a side contour line of the large complex curvature member to be processed and formed after roll bending;
1.4) dividing the curve L4 into n sections, wherein n is 2-10, the curvature of each section of the curve in the n sections is regarded as equal curvature, and the curvature radius of each section of the curve in the n sections is the curvature radius at the left end point or the right end point;
1.5) measuring the radius of curvature r of the left end point or the right end point of each curve in the curve L4iObtaining the roll bending upper roll pressing quantity d of each section of the curve according to finite element simulation calculationi1, 2 …. n;
1.6) obtaining the upper roll pressing amount d according to calculationiAnd performing sectional roll bending on the component.
3. The method for accurately forming a large-scale complex curvature member according to claim 2, wherein: the specific implementation manner of the step 2) is as follows:
2.1) carrying out vacuum bag sealing on the roll-bent raw plate of the large complex curvature component;
2.2) after the vacuum bag is sealed, putting the whole of the original plate and the mould of the large-scale complex curvature component into an autoclave for vacuumizing, heating and boosting;
2.3) preserving heat and pressure for 5-25h, and generating creep deformation in the large complex curvature component to be processed; and (3) cooling and pressure relief are carried out after the experiment, and the component is taken out when the temperature is reduced to 50-60 ℃, so that the large complex curvature component formed with high precision is finally obtained.
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| US20200222967A1 (en) * | 2019-01-11 | 2020-07-16 | Embraer S.A. | Methods for producing creep age formed aircraft components |
| CN110496899B (en) * | 2019-08-15 | 2021-07-06 | 江南造船(集团)有限责任公司 | Method and apparatus for forming plate |
| CN110907296A (en) * | 2019-12-05 | 2020-03-24 | 中南大学 | Method for identifying flow times of dynamic creep test of asphalt mixture |
| CN111546542B (en) * | 2020-06-23 | 2022-05-27 | 江苏铁锚玻璃股份有限公司 | Large-curvature organic glass forming die and manufacturing method thereof |
| CN113688468B (en) * | 2021-09-10 | 2023-06-27 | 中南大学 | Compensation method for creep aging simulation complex molded surface |
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|---|---|---|---|---|
| JPH0377721A (en) * | 1989-08-21 | 1991-04-03 | Kawatetsu Techno Res Corp | Bending method for laminated steel plate |
| GB2425079A (en) * | 2005-04-11 | 2006-10-18 | Rolls Royce Plc | Method of manufacturing a duct for a gas turbine engine |
| CN104561848A (en) * | 2014-12-26 | 2015-04-29 | 中国航空工业集团公司北京航空制造工程研究所 | Creep age forming technological method |
| CN105598250A (en) * | 2016-03-18 | 2016-05-25 | 西北工业大学 | Magnetic pulse local loading forming device and method for skin panel |
| CN106978578A (en) * | 2017-05-18 | 2017-07-25 | 中南大学 | A kind of aluminium alloy plate creep age forming method |
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2018
- 2018-07-31 CN CN201810858666.9A patent/CN109092944B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0377721A (en) * | 1989-08-21 | 1991-04-03 | Kawatetsu Techno Res Corp | Bending method for laminated steel plate |
| GB2425079A (en) * | 2005-04-11 | 2006-10-18 | Rolls Royce Plc | Method of manufacturing a duct for a gas turbine engine |
| CN104561848A (en) * | 2014-12-26 | 2015-04-29 | 中国航空工业集团公司北京航空制造工程研究所 | Creep age forming technological method |
| CN105598250A (en) * | 2016-03-18 | 2016-05-25 | 西北工业大学 | Magnetic pulse local loading forming device and method for skin panel |
| CN106978578A (en) * | 2017-05-18 | 2017-07-25 | 中南大学 | A kind of aluminium alloy plate creep age forming method |
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