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橡皮成形是飞机钣金零件制造的一种重要的成形工艺,为提高典型零件橡皮成形的效率,针对橡皮成形过程中产生的起皱问题,基于响应面法对侧压块参数进行优化.首先对新淬火状态下的铝合金板料进行材料试验,分析了其成形性能指标参数,为有限元模拟提供材料本构关系与模型;然后以起皱量化为优化目标,将凸弯边的最大增厚率作为侧压块优化的目标函数,为得到典型零件橡皮成形侧压块精确的几何参数,采用Abaqus有限元软件对带侧压块成形过程进行正交模拟试验,得出侧压块几何参数对起皱指标影响程度得主次关系,并得到最优的参数水平组合.基于响应面建模方法建立了侧压块最优几何参数和起皱指标之间的多项式关系,并用遗传算法进行参数优化,利用优化后的工艺参数进行有限元模拟,阐述了侧压块防皱原理;最后通过实际成形试验,验证了有限元模拟的可行性和优化方法的可靠性.
Rubber forming is an important forming process for aircraft sheet metal parts manufacturing. In order to improve the efficiency of rubber molding of typical parts, the side pressing parameters are optimized based on the response surface method for the wrinkling problem in the rubber forming process.Firstly, In the newly quenched aluminum alloy sheet, the material test was carried out, and the forming performance index parameters were analyzed to provide material constitutive relation and model for the finite element simulation. Then the crease quantification was taken as the optimization goal, In order to obtain the accurate geometrical parameters of the rubber-formed side briquette, the Abaqus finite element software was used to carry out the orthogonal simulation test of the side-briquette forming process. The geometric parameters of the side-briquette The degree of influence of wrinkle index has primary and secondary relationship, and get the optimal combination of parameter level.Based on the response surface modeling method, the polynomial relationship between the optimal geometry parameters and wrinkling index of lateral pressure block is established and the genetic algorithm is used to optimize the parameters, The finite element simulation is carried out by using the optimized process parameters, and the principle of anti-wrinkle of the side briquetting block is expounded. Finally, the actual forming test is carried out to verify that the finite element simulation Row and reliability optimization method.