目的 针对采用传统热成形方式制造航空飞机带板零件时存在的工艺周期长、成形性能差等问题,进行电辅助冲压成形技术基础研究,以确定工艺方案设计和缺陷控制方法。方法 通过AutoFormR10软件进行数值模拟,确定了该零件无起皱开裂缺陷的成形方案,并基于传统热成形工艺的局限性,提出了电辅助冲压成形工艺。通过Abaqus数值模拟与热失稳图相结合的方式确定了最优的工艺方案,并开展了电场辅助冲压成形试验,对工艺方案进行了验证。结果 采用冲压成形的方式并降低模具翻边区域的高度,即可成形出无缺陷的带板零件;要将TA32坯料温度加热至800~1 000 ℃,需选择输出电流不低于1 700 A的直流电源;在电辅助冲压成形过程中,板料温度大幅下降,中心区域温度下降可达400 ℃,两侧靠近加强筋圆角处温度下降200 ℃;带板加强筋中间及圆角处同时为高应变区域和高应力区域,且温度低于安全加工窗口,故该区域最容易产生失稳缺陷;加强筋中间处安全温度窗口为740~860 ℃,圆角处安全温度窗口随应变变化而变化。结论 当加热后温度在950 ℃以上,并采用二次成形的方案,可以成形出无缺陷的带板零件,并通过电辅助冲压成形试验验证了此工艺方案的可行性。
Abstract
To address issues including long process cycles and poor formability in manufacturing aircraft strap components by conventional hot forming, the work aims to conduct fundamental research on electrically assisted stamping technology for determining process solution design and defect control methods. Numerical simulation via AutoFormR10 software was employed to determine a forming solution for the component without wrinkling or cracking defects. Based on the limitations of conventional hot forming processes, an electrically assisted stamping forming process was proposed. By combining Abaqus numerical simulation with thermal instability diagrams, the optimal process solution was determined, and electrically assisted stamping forming experiments were conducted to validate the process solution. By adopting the stamping forming method and reducing the height of the die flange area, a defect-free strap component could be formed. To heat the TA32 blank to a temperature range of 800 ℃ to 1 000 ℃, a DC power supply with an output current of at least 1 400 A to 1 700 A must be selected. During the electrically assisted stamping forming process, the temperature of the strap dropped significantly, with a decrease of up to 400 ℃ in the central region and a 200 ℃ drop on both sides near the rounded corners of the stiffeners. The middle and rounded corners of the strap stiffeners were identified as both high-strain and high-stress regions, with temperatures below the safe processing window, making them the most prone to instability defects. The safe temperature window for the middle of the stiffeners was determined to be 740-860 ℃, while for the rounded corners, the safe temperature window varied with strain. By heating the material to above 950 ℃ and adopting a two-step forming solution, defect-free strap components can be formed. The feasibility of this process solution is validated through electrically assisted stamping forming experiments.
关键词
TA32 /
电辅助冲压 /
成形缺陷 /
多场耦合
Key words
TA32 /
electrically assisted stamping /
forming defects /
multi-field coupling
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基金
国家自然科学基金（92371106）; 北京市自然科学基金（L247019）
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