GLARE板三维曲面多点热压成形新技术的理论与实验研究

In order to solve the key challenges associated with forming process of three-dimensional(3D) GLARE panels, this project will study the formation mechanisms and key technologies in manufacturing the contour of 3D GLARE panels by multi-point thermoforming, which is originally developed based on the multi-point flexible forming methodology and consist of a multi-point die, a hot-forming press system of silicone rubber flexible film, an electric heating system of multi-punch, and a flexible thermo-elastic cushion. On the theoretical research, the structure stability of interface adhesion (density of states and binding energy), geometric transformation of curve radius, and the internal stress in formed parts will be simulated by first-principle calculation, mapping computation and finite element method, respectively. The simulation is based on the constitutive model of GLARE, which is founded by the biaxial tensile strength testing, in situ tests for micro-mechanics, etc. The formation mechanisms and new forming technique of multi-point thermoforming for 3D GLARE panels can be clarified by the above multi-scale and collaborative simulation. On the experimental research, lots of forming experiments for 3D GLARE panels will be done using the prototype multi-point thermoforming machine, which is originally developed in this project. In addition, the coupling mechanism of response in the forming accuracy, surface quality, raw material performance, mold surface, forming temperature and press, can be clarified by microstructure characterization and non-contact measurement. This work can found the research system with sustainable manufacturing and integrated design for 3D GLARE panels. Furthermore, the basic theory and technology of prototype multi-point thermoforming machine for 3D GLARE panels also can be founded successfully, which is a new method with low cost in green manufacturing of 3D GLARE panels.

针对GLARE板三维曲面成形理论不完善、制造成本高等问题，基于多点柔性成形方法，通过将单个多点数字化模具（下模）与开发的硅橡胶软膜热压系统、多点冲头电加热系统、柔性加热垫集成，开展GLARE板曲面多点热压成形原型样机的创新设计、成形机理与关键技术研究。理论研究方面：借助材料参数测试，构建GLARE板本构模型，结合第一性原理、映射和有限元计算，开展粘接面态密度与结合能等组织结构稳定性、成形曲率几何变换、成形件内部应力与外部载荷状态等多尺度协同仿真，揭示曲面成形机理。实验研究方面：借助原型样机，开展多种GLARE板曲面成形实验，结合微观表征与三维测量，阐明成形件的精度、表面质量与坯料性能、模具型面、成形温度和压力等多参数的耦合响应机制。最终，构建GLARE板曲面可持续制造与一体化设计研究平台，形成GLARE板曲面多点热压成形理论和原型样机技术基础，为GLARE板曲面低成本、绿色制造提供新方法。

GLARE板兼具金属合金与纤维/树脂复合材料的优点而又克服了各自缺点，在新一代航空、航天、轨道交通、汽车等领域具有广阔的应用前景。为实现 GLARE 板及其曲面成形件的低成本、可持续、绿色制造，本项目基于多点模具型面的可柔性变化特点，开展了GLARE 板结构/性能仿真分析、原型样机设计制造与调试、成形特性调控、成形质量评测与实验平台搭建等内容研究工作。发明了基于多点可重构模具的复合材料曲面热压成型方法、一种复合材料自动切料设备及切料方法、以及一种复合材料带筋板零件热压柔性成形设备。建立了GLARE板仿真分析及新结构设计体系，获得了不同结构的GLEARE板材料性能关键数据，改变 GLARE 板曲面成形工艺控制长期依赖“试错法”的现状。完成了GLARE 板曲面多点热压成形工程样机的设计制造与调试、及成形特性调控，搭建了GLARE板成形实验与质量评测平台；揭示了成形件的精度、表面质量与坯料性能、模具型面、成形温度和压力等多参数的耦合响应机制，以及纤维铺排角度、金属体积分数、纤维/金属种类与GLARE 板曲面成形特性内在影响机制，为 GLARE 板曲面成形及零件塑性加工奠定理论基础。实现了GLARE板所属的层状复合材料的机械性能与电储能性能耦合，获得了兼具承载与储能特性的层状功能复合材料。项目成果在航空航天、轨道交通等多品种、小批量、高性能零部件的制造领域具有广阔应用前景。