电磁渐进柔性复合成形大型金属板材的基础研究

With the development of the high technology, such as large aircraft and new generation carrier rocket. Large scale shell and difficult deformation of integral manufacture metal part has become vital demand in the aerospace field. How to realize the large and high strength difficult deformation of the workpiece integrated manufactured, which is the key problem need to urgently solved in the aerospace field. In order to solve this problem，this project brings forward a novel technology for forming the large scale and difficult deformation of the shell part, named electromagnetic incremental flexible forming. The internal relations of the pre-tension stress, intermediate transition shape, discharge parameters and deformation uniformity will be researched，via theoretical analysis, experiments, numerical simulation and testing technologies. The effect of pre-tension stress, sheet intermediate transition shape, discharge parameters, coil structure，moving interval, loading trajectory and elastic medium parameters on plastic coordination deformation behavior of workpiece is systematacially investigated. The plastic deformation behavior and forming mechanism of electromagnetic incremental flexible composite forming will be disclosed. Then electromagnetic incremental flexible composite forming parameters are optimized on the previous results. The relationship of "technology-organization -performance" will be developed. A new process theory and quality control technique for electromagnetic incremental flexible composite forming technology are formed. It will provide theoretical foundation and technical support for precise plastic forming of large scale shell parts in our country aerospace field.

随着大飞机、新一代运载火箭等高新技术的发展，大型壳体类轻质难变形金属零件整体成形制造已成为我国航空航天领域的重大需求，如何实现大型轻质高强度难变形工件的整体成形成性一体化制造，是航空航天领域迫切需要解决的关键难题。本项目提出电磁渐进柔性复合成形新技术加工大型难变形壳体零件，解决其成形制造难题。通过采用理论分析、实验研究、数值模拟以及分析测试等手段，研究预拉应力、中间过渡形状以及放电参数与变形均匀性的内在联系，系统考察预拉应力、中间过渡形状、放电参数、线圈结构、移动步距、加载轨迹以及弹性介质等参数对工件的塑性协调变形行为的影响规律，揭示电磁渐进柔性复合成形塑性变形行为与成形机理。在此基础上，优化电磁渐进柔性复合过程工艺参数，建立“工艺-组织-性能”的关系，形成新颖的电磁渐进柔性复合成形工艺理论和质量控制技术，为我国航空航天领域中大型壳体零件精确塑性成形成性提供理论基础与技术支持。

传统制造方法对大型壳体零件成形制造提出严峻的挑战，如何实现大型壳体铝合金等轻质合金零件的精确塑性成形制造，成为亟需解决的关键难题。本项目基于多点模电磁渐进复合成形工艺对大型工件进行成形，采用理论研究、数值仿真与试验研究相结合的方法对大型板材电磁渐进柔性复合成形进行了初步研究。研究了板材中间过渡形状的设计方法，并对中间过渡形状进行优化设计；探讨了成形道次对板材均匀变形的影响；分析了线圈与多点模球头相对位置关系对板材变形均匀性的影响规律；研究了线圈加载路径对板材均匀变形的影响规律。这些工艺参数相互协调匹配对板材变形均匀性影响的工作也正在进行中。上述的研究对大型板材电磁渐进柔性复合成形的塑性流动行为、实现大型工件成形成性一体化调控奠定了坚实的工作基础。项目资助发表SCI收录学术论文10篇，已授权国家发明专利3项，培养硕士研究生3名。