航天用铝合金渐进成形韧性断裂数值预测的研究进展

高正源; 李沛豪; 李正芳; 安治国; 李治兵; 孙鹏飞; 任重; 李江; 张义; 乔正阳

doi:10.3969/j.issn.1674-6457.2025.06.014

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精密成形工程 ›› 2025, Vol. 17 ›› Issue (6) : 129-142. DOI: 10.3969/j.issn.1674-6457.2025.06.014

轻合金成形

航天用铝合金渐进成形韧性断裂数值预测的研究进展

高正源¹, 李沛豪¹, 李正芳^2*, 安治国¹, 李治兵¹, 孙鹏飞¹, 任重³, 李江⁴, 张义⁴, 乔正阳⁵

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Investigation Progress on Numerical Prediction of Toughness Fracture in Incremental Forming of Aluminum Alloys for Aerospace Applications

GAO Zhengyuan¹, LI Peihao¹, LI Zhengfang^2*, AN Zhiguo¹, LI Zhibing¹, SUN Pengfei¹, REN Zhong³, LI Jiang⁴, ZHANG Yi⁴, QIAO Zhengyang⁵

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摘要

随着现代工业的进步,为了满足航天制造和汽车工业领域日益增长的高精度定制零件需求,轻量化制造已成为航天和汽车工业的重要发展方向,其中渐进成形技术以其柔性无模的特性满足了高精度、低成本、个性化生产的需求。铝合金因其优异的比强度和成形性,成为渐进成形的首选材料,但其在复杂应力条件下易发生韧性断裂,这对零件的质量和性能提出了挑战。近年来,随着计算机等相关学科的进步,有限元仿真技术与相关韧性断裂准则已成为预测铝合金成形断裂缺陷的重要手段。本文总结了材料发生塑性变形时的本构模型,并对宏观场景下快速预测的耦合韧性断裂准则与微观分析和高精度模拟的非耦合韧性断裂准则的研究现状进行了详尽综述,探讨了各类本构模型和断裂准则在渐进成形中的适用性和精度,同时分析了通过优化网格尺寸、温度和刀具路径等工艺参数来提高成形性能并提升断裂预测精度的方法。最后,结合实验与数值仿真结果,验证了数值仿真在预测韧性断裂缺陷方面的准确性,并综述了工艺参数对材料韧性断裂预测精度的影响。在此基础上,未来应聚焦于提升铝合金渐进成形性能和断裂预测精度,发展更精确的本构模型与韧性断裂准则,优化温度、网格尺寸和刀具路径等工艺参数。同时,探索新型铝合金及复合材料的断裂预测方法,结合多场耦合仿真技术,为高端制造中的应用提供支持。

Abstract

With the advancement of the modern industry, lightweight manufacturing has become a critical development direction in the aerospace and automotive industries to meet the growing demand for high-precision customized components. Incremental forming technology, characterized by its flexible, die-less process, addresses the demands of high precision, low cost, and personalized production. Aluminum alloys, due to their excellent specific strength and formability, have become the preferred materials for incremental forming. However, their susceptibility to ductile fracture under complex stress conditions poses challenges to the quality and performance of formed components. In recent years, advancements in computational technologies have made finite element simulation, combined with ductile fracture criteria, a key tool for predicting aluminum alloy fracture during forming. This paper reviews constitutive models for plastic deformation and provides a detailed summary of the research progress on coupled ductile fracture criteria for macroscopic fast predictions and uncoupled criteria for microscopic high-precision simulations. The applicability and accuracy of various constitutive models and fracture criteria in incremental forming are explored, along with methods to improve forming performance and fracture prediction accuracy by optimizing process parameters such as mesh size, temperature, and toolpath. Additionally, experimental and numerical results validate the accuracy of simulations in predicting ductile fracture, and the influence of process parameters on the accuracy of material toughness fracture prediction is summarized. Therefore, future research should focus on enhancing forming performance and fracture prediction accuracy, developing more precise constitutive models and fracture criteria, optimizing process parameters such as mesh size, temperature, and toolpath, exploring fracture prediction methods of novel aluminum alloys and composites, and coupling these efforts with multi-field simulation techniques to support high-end manufacturing applications.

导出引用

高正源, 李沛豪, 李正芳, 安治国, 李治兵, 孙鹏飞, 任重, 李江, 张义, 乔正阳. 航天用铝合金渐进成形韧性断裂数值预测的研究进展[J]. 精密成形工程. 2025, 17(6): 129-142 https://doi.org/10.3969/j.issn.1674-6457.2025.06.014

GAO Zhengyuan, LI Peihao, LI Zhengfang, AN Zhiguo, LI Zhibing, SUN Pengfei, REN Zhong, LI Jiang, ZHANG Yi, QIAO Zhengyang. Investigation Progress on Numerical Prediction of Toughness Fracture in Incremental Forming of Aluminum Alloys for Aerospace Applications[J]. Journal of Netshape Forming Engineering. 2025, 17(6): 129-142 https://doi.org/10.3969/j.issn.1674-6457.2025.06.014

中图分类号： TG335

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