单条边或多条边带弧度翻边钣金件，在航空航天中应用广泛。采用机器人柔性翻边成形技术可克服传统手工成形劳动强度大，效率低，产品质量一致性和可靠性难以保证等局限性，实现多品种、小批量翻边钣金件快速精确成形制造。然而，机器人柔性翻边成形技术属于轨迹控制的局部加载成形技术，在成形过程中易出现自由端塌陷及回弹等缺陷。针对此问题，以典型特征翻边件为研究对象，采用有限元仿真和实验相结合的方法，分析了柔性翻边成形过程中塌陷形成机理，进而系统开展机器人柔性翻边成形轨迹优化研究。研究结果表明：成形滚轮切入轨迹对翻边件自由端塌陷影响最大，应选择自由端预压方案，且切入点距自由端距离取值为20 mm时改善效果最好；采用优化后的成形滚轮切入切出轨迹进行柔性翻边成形实验，可获得自由端无塌陷、翻边开角误差小于0.5°及过渡圆角半径误差小于0.5 mm的翻边件。

A certain edge or multiple edges with curved flanged sheet metal parts are widely used in aerospace. The use of robot-assisted flexible flanging technology can overcome the limitations of traditional manual forming such as high labor intensity， low efficiency， and difficulty in guaranteeing the consistency and reliability of product quality， and realize the rapid and accurate forming of multi-passes and small-patch flanged sheet metal parts. However， robot-assisted flexible flanging technology is a trajectory-controlled local loading forming technology， which is prone to such defects as free end collapse and springback during the forming process. Combined finite element simulation with experiment， the mechanism of collapse formation in the flexible flanging process is analyzed； the robot flexible flanging trajectory optimization is then studied. The results of the study show that the rolling-in trajectory of the forming roller has the greatest influence on the free end collapse of the flanged part， and the best improvement effect is achieved when the free end pre-forming scheme is selected and the distance from the rolling-in point to the free end is 20 mm. Based on the optimized forming roller rolling-in and rolling-out trajectory， the flanged parts can be obtained without free end collapse， and the error of the flanging opening angle and the fillet radius is less than 0.5° and 0.5 mm， respectively.