整体壁板离散填料滚弯成形有限元模拟

具有一定曲率外形的铝合金整体壁板属于典型的多筋零部件,传统弯曲成形工艺成形困难,容易产生多种缺陷。提出了离散填料辅助滚弯成形整体2A12T4铝合金壁板滚弯工艺,并通过实验与整体填料滚变成形进行了对比,同时采用有限元模拟技术,探究了离散填料辅助整体壁板滚弯成形中的影响因素。研究结果表明:填料数量、上下垫板厚度等因素对成形性能影响较大,填料在3~6块时成形稳定,可以有效地避免筋条屈曲与失稳;随垫板厚度增加,壁板表面圆弧更加光滑、连续,但是回弹性增强;上下垫板分别在10~20 mm厚度时,综合性能较好。通过离散填料辅助滚弯技术可以成形出质量较高的整体壁板。

Finite element simulation on discrete filling rolling for integral panel skins

The integral panel skins of aluminum alloy with a certain curvature is a typical component with multi-ribs which is difficult to form and easy to produce various defects by traditional bending process. Therefore,the discrete filling assisted rolling for integral panel skins of 2 A12 T4 aluminum alloy was proposed and compared with the overall filling rolling through experiments. At the same time,the influent factors in the discrete filling assisted rolling of integral panel skins were explored by the finite element simulation technology. The results show that the number of filler and the thickness of upper and lower backing plates have a great influence on the forming quality,and when the number of filler is 3-6,the forming is stable to avoid rib buckling and instability. Furthermore,with the increasing of the thickness for backing plate,the circular arc on the surface of panel skins is smoother and more continuous,but the springback is enhanced. When the thickness of upper and lower backing plates is 10-20 mm respectively,the comprehensive performance of the integral panel skins is better. Thus,the discrete filling assisted rolling technology can form the high-quality integral panel skins.