面向航空铝合金薄壁深腔构件的冲击液压成形工艺优化

doi:10.7527/S1000-6893.2020.24831

论文

本期目录 | 过刊浏览 | 高级检索

前一篇 | 后一篇

面向航空铝合金薄壁深腔构件的冲击液压成形工艺优化

徐勇^1,2, 尹阔², 夏亮亮¹, 门向南³, 曾一畔³, 张士宏¹

1. 中国科学院金属研究所师昌绪先进材料创新中心, 沈阳 110016;
2. 华北理工大学冶金与能源学院, 唐山 063210;
3. 航空工业成都飞机工业(集团)有限责任公司, 成都 610092

收稿日期:2020-10-09 修回日期:2020-10-28 发布日期:2020-12-25
通讯作者: 张士宏 E-mail:shzhang@imr.ac.cn
基金资助:
国家自然科学基金（51875548）；四川省科技计划项目（2019YFSY0050）

Optimization of impact hydroforming process for aeronautical components of aluminum alloy sheets with thin wall and deep cavity

XU Yong^1,2, YIN Kuo², XIA Liangliang¹, MEN Xiangnan³, ZENG Yipan³, ZHANG Shihong¹

1. China Shi-Changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China;
2. College of Metallurgy and Energy, North China University of Science and Technology, Tangshan 063210, China;
3. AVIC Chengdu Aircraft Industrial(Group) Co. Ltd., Chengdu 610092, China

Received:2020-10-09 Revised:2020-10-28 Published:2020-12-25
Supported by:
National Natural Science Foundation of China (51875548); Sichuan Science and Technology Program (2019YFSY0050)

摘要/Abstract

摘要： 为实现冲击液压成形下LY12铝合金薄壁深腔构件的一道次成形，采用响应面法结合冲击液压成形实验进行成形中的工艺参数优化研究。以减薄率和贴模率为响应量，压边力和冲击压力为优化变量，建立响应量与优化变量间的响应模型。选择中心复合设计法进行实验设计，通过Design Expert 12软件设计实验方案，分别建立关于减薄率的一阶响应模型和关于贴模率的二阶响应模型。优化结果表明当压边力为1.443 MPa、冲击压力为12.594 MPa时可满足减薄率和贴模率优化条件。通过验证实验得到的筒形件其减薄率和贴模率与预测值相对误差不超过5%。研究结果表明建立的响应面模型准确性和预测性良好，采用优化后的工艺参数成形的筒形件满足减薄率和贴模率要求。

关键词: 航空复杂薄壁构件, 冲击液压成形, 响应面法, 中心复合设计, 工艺参数优化

Abstract: To realize one-step forming of aeronautical components of LY12 aluminum alloy sheets with thin wall and deep cavity by impact hydroforming, the response surface method combined with the impact hydroforming experiment was employed to optimize the process parameters. A model for the response between the response quantity and the optimization variable was established by taking the thinning rate and the sticking rate as the response quantity, and the blank holder force and impact force as optimization variables. The central composite design method was selected for experimental design, and experimental scheme was designed with the software of Design Expert 12. The first-order response model on the thinning rate and the second-order response model on the sticking rate were established. The optimization results show that when the blank holder force is 1.443 MPa and the impact force is 12.594 MPa, the requirements for thinning rate and filming rate can be reached at the same time. The relative error between the thinning rate and the predicted value is less than 5%. The results show that the proposed response surface model has good accuracy and predictability. The cylindrical components formed by the optimized process parameters meet the requirements on product quality.

Key words: aeronautical complex-shaped thin-walled component, impact hydroforming, response surface method, central composite design, process parameters optimization

中图分类号:

V261.7⁺4

徐勇, 尹阔, 夏亮亮, 门向南, 曾一畔, 张士宏. 面向航空铝合金薄壁深腔构件的冲击液压成形工艺优化[J]. 航空学报, 2021, 42(10): 524831-524831.

XU Yong, YIN Kuo, XIA Liangliang, MEN Xiangnan, ZENG Yipan, ZHANG Shihong. Optimization of impact hydroforming process for aeronautical components of aluminum alloy sheets with thin wall and deep cavity[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2021, 42(10): 524831-524831.

参考文献

[1] 宋拥政, 舒鑫源, 李中守. 航空航天钣金冲压件制造技术[M]. 北京:机械工业出版社, 2013:16-18. SONG Y Z, SHU X Y, LI Z S. Manufacturing technology of aerospace sheet metal stamping parts[M]. Beijing:China Machine Press, 2013:16-18(in Chinese).
[2] 骞西昌, 杨守杰, 张坤, 等. 铝合金在运输机上的应用与发展[J]. 轻合金加工技术, 2005, 33(10):1-7. QIAN X C, YANG S J, ZHANG K, et al. Development and application of aluminum alloys on the transport planes[J]. Light Alloy Fabrication Technology, 2005, 33(10):1-7(in Chinese).
[3] 罗先甫, 查小琴, 夏申琳. 2×××系航空铝合金研究进展[J]. 轻合金加工技术, 2018, 46(9):17-25. LUO X F, ZHA X Q, XIA S L. Research progress of 2×××series aviation aluminum alloys[J]. Light Alloy Fabrication Technology, 2018, 46(9):17-25(in Chinese).
[4] 刘兵, 彭超群, 王日初, 等. 大飞机用铝合金的研究现状及展望[J]. 中国有色金属学报, 2010, 20(9):1705-1715. LIU B, PENG C Q, WANG R C, et al. Recent development and prospects for giant plane aluminum alloys[J]. The Chinese Journal of Nonferrous Metals, 2010, 20(9):1705-1715(in Chinese).
[5] ROHATGI A, SOULAMI A, STEPHENS E V, et al. An investigation of enhanced formability in AA5182-O Al during high-rate free-forming at room-temperature:Quantification of deformation history[J]. Journal of Materials Processing Technology, 2014, 214(3):722-732.
[6] AZARYAN N S, SHIRKOV G D, ZHURAUSKI A Y, et al. Manufacture of superconducting niobium cavity parts by hydropercussion punching[J]. Physics of Particles and Nuclei Letters, 2016, 13(2):218-223.
[7] HOMBERG W, DJAKOW E, AKST O, et al. Investigation of a pneumo-mechanical high speed forming process with respect to the forming of complex sheet and tube components[J]. Journal of Mechanical Engineering NTUU, 2013, 67(1):180-185.
[8] KHODKO O, ZAYTSEV V, SUKAYLO V, et al. Experimental and numerical investigation of processes that occur during high velocity hydroforming technologies:An example of tubular blank free bulging during hydrodynamic forming[J]. Journal of Manufacturing Processes, 2015, 20:304-313.
[9] 郎利辉, 王少华, 杨春雷, 等. 新型冲击充液复合成形工艺及其关键技术研究[J]. 锻压技术, 2014, 39(7):1-5. LANG L H, WANG S H, YANG C L, et al. Research of innovative hybrid impact hydroforming process and its key technology[J]. Forging & Stamping Technology, 2014, 39(7):1-5(in Chinese).
[10] 徐勇, 张士宏, 马彦, 等. 新型液压成形技术的研究进展[J]. 精密成形工程, 2016, 8(5):7-14. XU Y, ZHANG S H, MA Y, et al. Hydroforming technology:State-of-the-arts and recent developments[J]. Journal of Netshape Forming Engineering, 2016, 8(5):7-14(in Chinese).
[11] 张士宏, 程明, 宋鸿武, 等. 航空航天复杂曲面构件精密成形技术的研究进展[J]. 南京航空航天大学学报, 2020, 52(1):1-11. ZHANG S H, CHENG M, SONG H W, et al. Research progress on precision forming technology for complex curved surface components in aerospace[J]. Journal of Nanjing University of Aeronautics & Astronautics, 2020, 52(1):1-11(in Chinese).
[12] MA Y, XU Y, ZHANG S H, et al. Investigation on formability enhancement of 5A06 aluminium sheet by impact hydroforming[J]. CIRP Annals, 2018, 67(1):281-284.
[13] ABD EL-ATY A, XU Y, ZHANG S H, et al. Impact of high strain rate deformation on the mechanical behavior, fracture mechanisms and anisotropic response of 2060 Al-Cu-Li alloy[J]. Journal of Advanced Research, 2019, 18:19-37.
[14] CHEN D Y, XU Y, ZHANG S H, et al. A novel method to evaluate the high strain rate formability of sheet metals under impact hydroforming[J]. Journal of Materials Processing Technology, 2021, 287:116553.
[15] XU Y, ABD EL-ATY A, ZHANG S H, et al. Effect of novel impact hydroforming technology on the formability of Al alloys[J]. IOP Conference Series:Materials Science and Engineering, 2019, 651:012053.
[16] ZHANG S H, MA Y, XU Y, et al. Effect of impact hydroforming loads on the formability of AA5A06 sheet metal[J]. IOP Conference Series:Materials Science and Engineering, 2018, 418:012114.
[17] CHU T H, FUH K H, YEH W C. Experimental optimization of deep drawing using response surface methodology[J]. Applied Mechanics and Materials, 2011, 121-126:1495-1499.
[18] 卢松涛, 王培安. 基于响应面法和正交试验的墨顶盖翘曲变形优化[J]. 塑料, 2020, 49(4):65-68, 72. LU S T, WANG P A. Optimization of warpage deformation of ink cap based on response surface method and orthogonal experiment[J]. Plastics, 2020, 49(4):65-68, 72(in Chinese).
[19] 姜天亮, 龚红英, 施为钟, 等. 基于响应曲面法U形件弯曲成形工艺参数优化[J]. 上海工程技术大学学报, 2019, 33(3):278-282. JIANG T L, GONG H Y, SHI W Z, et al. Process parameters optimization of U-shaped bending based on response surface methodology[J]. Journal of Shanghai University of Engineering Science, 2019, 33(3):278-282(in Chinese).
[20] BOX G E P, WILSON K B. On the experimental attainment of optimum conditions[J]. Journal of the Royal Statistical Society:Series B (Methodological), 1951, 13(1):1-38.
[21] HU W, ENYING L, YAO L G. Optimization of drawbead design in sheet metal forming based on intelligent sampling by using response surface methodology[J]. Journal of Materials Processing Technology, 2008, 206(1-3):45-55.
[22] 崔磊, 刘静, 李兰云. 基于响应面法的双层316L/Inconel625波纹管液压胀形工艺参数优化[J]. 兵器材料科学与工程, 2018, 41(6):19-26. CUI L, LIU J, LI L Y. Optimization of hydroforming process parameters of bi-layered 316L/Inconel625 bellows based on response surface method[J]. Ordnance Material Science and Engineering, 2018, 41(6):19-26(in Chinese).
[23] MUSAVI S H, DAVOODI B, ESKANDARI B. Evaluation of surface roughness and optimization of cutting parameters in turning of AA2024 alloy under different cooling-lubrication conditions using RSM method[J]. Journal of Central South University, 2020, 27(6):1714-1728.
[24] 胡成武, 李光, 毛远征, 等. 圆筒形件的拉深变形与应力分析[J]. 塑性工程学报, 2020, 27(3):130-136. HU C W, LI G, MAO Y Z, et al. Stress analysis and deformation of deep drawing for cylindrical part[J]. Journal of Plasticity Engineering, 2020, 27(3):130-136(in Chinese).
[25] 仇建桐, 邓沛然, 邵威, 等. 基于Dynaform的铝合金筒形件拉深成形[J]. 锻压技术, 2020, 45(5):49-55. QIU J T, DENG P R, SHAO W, et al. Deep drawing of cylindrical parts for aluminum alloy based on Dynaform[J]. Forging & Stamping Technology, 2020, 45(5):49-55(in Chinese).
[26] 陈绪国, 李继光, 张杰刚, 等. 2A12铝合金平底筒形件充液拉深数值模拟研究[J]. 精密成形工程, 2015, 7(6):86-91. CHEN X G, LI J G, ZHANG J G, et al. Numerical simulation of 2A12 aluminum flat bottom cylindrical part by hydromechanical deep drawing[J]. Journal of Netshape Forming Engineering, 2015, 7(6):86-91(in Chinese).
[27] 徐勇, 王震, 曾一畔, 等. LY12铝合金板材本构模型的构建及验证应用[J]. 塑性工程学报, 2020, 27(1):138-145. XU Y, WANG Z, ZENG Y P, et al. Establishment and verification of constitutive model of LY12 aluminum alloy sheet[J]. Journal of Plasticity Engineering, 2020, 27(1):138-145(in Chinese).
[28] LIU Y H, WANG J, WANG D H. Numerical optimization on hot forging process of connecting rods based on RSA with experimental verification[J]. The International Journal of Advanced Manufacturing Technology, 2017, 90(9-12):3129-3135.
[29] CHELLADURAI S J S, MURUGAN K, RAY A P, et al. Optimization of process parameters using response surface methodology:A review[J]. Materials Today:Proceedings, 2021, 37:1301-1304.
[30] WANG L, LEE T C. Controlled strain path forming process with space variant blank holder force using RSM method[J]. Journal of Materials Processing Technology, 2005, 167(2-3):447-455.

E-mail：hkxb@buaa.edu.cn

关于我们

期刊社服务

专业学科

封面文章

友情链接

主管单位：中国科学技术协会主办单位：中国航空学会北京航空航天大学

面向航空铝合金薄壁深腔构件的冲击液压成形工艺优化

Optimization of impact hydroforming process for aeronautical components of aluminum alloy sheets with thin wall and deep cavity

RichHTML

PDF (PC)

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 10

编辑推荐

Metrics

本文评价

[1]	张开铭, 王克鲁, 鲁世强, 柳木桐, 钟平, 田野. 基于响应面法的S280超高强度不锈钢的热变形行为[J]. 航空学报, 2023, 44(8): 427293-427293.
[2]	王燕, 李书, 许秋怡, 马骏. 复合材料加筋板剪切后屈曲分析与优化设计[J]. 航空学报, 2016, 37(5): 1512-1525.
[3]	费成巍, 白广忱. 基于DCRSM的HPT叶尖径向运行间隙可靠性分析[J]. 航空学报, 2013, 34(9): 2141-2149.
[4]	赵威, 王伟. 非线性偏最小二乘回归法在均匀设计响应面法中的应用 [J]. 航空学报, 2012, (5): 839-847.
[5]	张军红, 韩景龙, 王晓庆. 具有随机不确定性的机翼颤振优化[J]. 航空学报, 2011, 32(9): 1629-1636.
[6]	姜琬;金海波;孙卫平. 基于多级响应面法的翼梢小翼气动优化设计[J]. 航空学报, 2010, 31(9): 1746-1751.
[7]	吕震宙;杨子政;赵洁. 基于加权线性响应面法的神经网络可靠性分析方法[J]. 航空学报, 2006, 27(6): 1063-1067.
[8]	刘成立;吕震宙. 结构可靠性分析中考虑高次项修正的组合响应面法[J]. 航空学报, 2006, 27(4): 594-599.
[9]	熊俊涛;乔志德;韩忠华. 基于响应面法的跨声速机翼气动优化设计[J]. 航空学报, 2006, 27(3): 399-402.
[10]	郭勤涛;张令弥;费庆国. 用于确定性计算仿真的响应面法及其试验设计研究[J]. 航空学报, 2006, 27(1): 55-61.