新型铝锂合金整体壁板弯曲成形缺陷预测及控制技术研究

Integral Panels are widely used today on advanced aircrafts because of their light weight and high stiffness. “Integral Panels” means skin and stringers are integrated into a single structure. But because of the complexity of the structure, the high precision of the contour, and the requirements of good mechanical properties, fabrication of this kind of aircraft panel becomes a great challenge to the aircraft manufacturing industry. Research on the forming of long life and low cost aircraft wing panels and fuselage panels is urgently needed. But press bend forming is operator dependent and the process parameters should be chosen carefully to avoid buckling and fracture on stiffeners and to form the desired contour. So the key manufacturing technology of the integral panels forming is effective defect prediction and Springback prediction. In order to establish an manufacture with low fatigue damage for 2A66 Al-Li alloy integral panel press bend forming process, a special simulation procedure and a calculation method for the punch and die boundary condition based on the bending line coordinates were proposed. The result from this project can provide the scientific guidance and technical support for the digitized manufacturing technique of 2A66 Al-Li alloy integral panel，and have a significant theoretical value and scientific significance.

实现成形过程回弹预测及缺陷预报，是整体壁板数字化制造技术的关键。本项目针对纵向筋条加强薄壁高弹性模量新型铝锂合金整体壁板在三支点受力条件下断续弯曲实现低疲劳损伤成形的制造机理这一核心科学问题，从弯曲成形外形仿真研究，成形缺陷预测模型研究和有限元等效模型集成及验证技术研究三个方面出发，剖析2A66铝锂合金整体壁板的回弹机制，阐明2A66铝锂合金在三支点受力条件下韧性开裂和失稳的预报及控制机理，初步获得新型国产铝锂合金整体壁板低损伤数字化制造技术原型。

针对整体壁板成形过程发生的回弹及缺陷实现有效预测，是整体壁板数值化制造技术的关键。本项目针对纵向筋条加强薄壁高弹性模量新型铝锂合金整体壁板在三支点受力条件下断续弯曲实现低疲劳损伤成形的制造机理这一核心科学问题，从弯曲成形外形仿真研究，缺陷预测材料模型研究和有限元等效模型集成及验证技术研究三个方面出发，剖析2A66铝锂合金整体壁板的回弹机制，阐明2A66铝锂合金在三支点受力条件下韧性开裂和失稳的预报及控制机理，初步获得新型国产铝锂合金整体壁板低损伤数字化制造技术原型。