CN110252881B - Creep age forming regulation and control method - Google Patents
Creep age forming regulation and control method Download PDFInfo
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- CN110252881B CN110252881B CN201910574113.5A CN201910574113A CN110252881B CN 110252881 B CN110252881 B CN 110252881B CN 201910574113 A CN201910574113 A CN 201910574113A CN 110252881 B CN110252881 B CN 110252881B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D31/00—Other methods for working sheet metal, metal tubes, metal profiles
- B21D31/005—Incremental shaping or bending, e.g. stepwise moving a shaping tool along the surface of the workpiece
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
Abstract
The invention provides a creep age forming regulation and control method, wherein a plurality of samples are cut on an aluminum alloy plate blank before the aluminum alloy plate blank is cut, the included angles between the length direction of each sample and the rolling direction of the aluminum alloy plate blank are different, each sample is clamped into a creep testing machine, a creep test is carried out on each sample, the creep amount of each sample is measured in real time, and the length direction of the sample with the largest creep amount and the fastest creep speed is taken as the main forming direction of the aluminum alloy plate. According to the invention, the creep performance of the aluminum alloy plate blank along each direction is tested in the creep testing machine, the optimal forming direction of the aluminum alloy plate blank is determined, and then the aluminum alloy plate blank is cut and blanked, so that the forming limit of the aluminum alloy plate can be improved, the aluminum alloy plate can reach a larger curvature at a higher speed, the load, time or temperature required for reaching the target forming curvature can be reduced, and the success rate and efficiency of creep forming are improved.
Description
Technical Field
The invention relates to a creep age forming technology, in particular to a creep age forming regulation and control method.
Background
The creep age forming technology is a novel forming technology which ingeniously combines the creep behavior and the aging strengthening behavior of metal, utilizes the creep deformation of a metal material after the metal material is kept for a period of time under the combined action of artificial aging temperature and elastic stress to obtain a member with a certain shape, and has the advantages of small damage, high forming precision, small residual stress, good repeatability and the like. With the continuous progress of China's industry, China's aerospace technology is rapidly developed, and the creep age forming technology is continuously advanced, so that the creep age forming technology becomes an indispensable large-scale wall plate forming technology in the field of aerospace product manufacturing. In the creep age forming process, the size of the forming amount is always a problem of great concern, which directly affects the maximum curvature that the component can form, the forming limit (i.e. the maximum forming amount) of the material includes creep deformation and plastic deformation, the forming limit determines the maximum curvature that can be obtained, as the specification and the type of the aerospace product are continuously increased, the maximum curvature of the component to be obtained is also increased, the larger the curvature (i.e. the more curved the product is), the more difficult the component is to be formed, the size required by the aerospace product is continuously increased, and the requirements on the maximum forming limit of creep and the forming efficiency are also continuously improved.
In the prior art, methods for improving the forming amount of a material mainly include increasing creep aging time, increasing creep aging temperature, increasing loading load and changing pre-deformation, too long time or too high temperature can cause the strength of a test piece to be weakened, the service performance is affected, increasing load can cause buckling or wrinkling (a destabilization phenomenon) with high probability, forming fails, increasing pre-deformation can cause the elongation of the test piece to be reduced, and challenges are brought to the subsequent welding process, so the methods have self limitations. At present, the material of large-scale wallboards such as wing wallboards, rocket tanks and the like mostly adopts high-strength aviation aluminum alloy, in the creep forming process, an aluminum alloy plate is firstly placed on a forming die, then is transferred to a hot-pressing tank and is processed into curved surface components (such as a melon petal-shaped curved surface for splicing a hemispherical surface and an arc-shaped surface for splicing a cylindrical surface) by using the creep age forming process, then a plurality of curved surface components are spliced and welded into an integral large component (such as a hemispherical surface or a cylindrical component), the aluminum alloy plate is mostly processed by adopting the rolling process, the placing mode of the aluminum alloy plate on the forming die at present keeps the length direction of the aluminum alloy plate coincident with the rolling direction of the aluminum alloy plate, and the rolling direction is not necessarily the direction which is the easiest to creep form, so the placing mode is not the most favorable for the creep forming of the aluminum alloy plate, namely the forming limit of, this results in a large integral member requiring a curved member to be divided into a plurality of small pieces or requiring a long forming time. The smaller the forming limit is, the more the number of needed parts is, or the longer the forming processing time is, but the current aerospace products such as airplanes and rockets are developed towards large tonnage and large volume, which will make the larger the single whole body is, the more the number of small curved surface members needed to be separated is, which will increase the manufacturing difficulty, reduce the production efficiency, and be unfavorable to the quality of the product, therefore, a solution is needed in the prior art to solve the problem.
Disclosure of Invention
The invention aims to provide a creep age forming regulation and control method to solve the problems in the background technology.
A creep age forming regulation method specifically comprises the steps of besides regulating and controlling at least one factor of aging time, aging temperature, loading load and pre-deformation in the creep age forming process, also considering and regulating and controlling the factor of an included angle between the rolling direction of an aluminum alloy plate and a plane where a curve with the maximum curvature is located on a formed curved surface member, namely a mold profile in the creep age forming process, so as to obtain the best cutting and blanking mode before creep age forming and/or the best creep age forming mold design mode, and further improve the forming efficiency of the aluminum alloy member during creep forming and/or ensure that the creep formed aluminum alloy member has ideal product performance.
Further, the investigation and regulation of the factor of the included angle between the rolling direction of the aluminum alloy plate and the plane of the curve with the maximum curvature on the mould surface in the creep age forming process specifically comprises the following steps:
s1) cutting a plurality of samples with the same size and contour on the aluminum alloy plate blank to be formed, wherein included angles between the length direction of each sample and the rolling direction of the aluminum alloy plate blank are different;
s2) adding each sample into a creep testing machine, and preparing to carry out creep tensile or compression tests on each sample, wherein the tensile or compression direction of the sample is kept the same as the length direction of the sample;
s3) carrying out creep tensile or compression test on each sample under the same conditions of load, temperature and loading time, and measuring the creep amount of each sample along the length direction in real time in the test process;
s4) taking the length direction of the sample with the largest creep amount and the fastest creep speed as the main forming direction M of the aluminum alloy plate to be cut for creep age forming, and accordingly cutting the aluminum alloy plate blank, wherein the main forming direction M of the aluminum alloy plate refers to the direction parallel to the plane of the curve with the largest curvature on the molded curved surface member, namely the mold profile;
the curved surface component is a two-way bent melon petal-shaped wallboard or a one-way bent semi-cylindrical wallboard.
In the plurality of samples, the included angle between the length direction of one sample and the rolling direction L of the aluminum alloy plate blank is equal to 0 degree, the included angle between the length direction of the other sample and the rolling direction L of the aluminum alloy plate blank is equal to 90 degrees, and the included angle between the length direction of at least one sample and the rolling direction of the aluminum alloy plate blank is larger than 0 degree and smaller than 90 degrees
Among the samples of which the included angle between the length direction and the rolling direction of the aluminum alloy plate blank is more than 0 degree and less than 90 degrees, the included angle between the length direction of one sample and the rolling direction of the aluminum alloy plate blank is equal to 45 degrees, and the included angles between the length direction of the other two samples and the rolling direction of the aluminum alloy plate blank are respectively equal to 30 degrees and 60 degrees.
The creep test temperature of the sample in the creep test machine is equal to the creep aging temperature to be implemented by the aluminum alloy plate in the actual autoclave, and the creep test time of the sample in the creep test machine is greater than or equal to the creep aging time to be implemented by the aluminum alloy plate in the actual autoclave; the change relation between the creep test load of the sample in the creep test machine and the creep quantity of the sample is used for providing the change relation to a finite element simulation system as a parameter for simulating and calculating the required applied air pressure in the autoclave.
Preferably, the aluminum alloy plate blank is subjected to solution heat treatment, is subjected to rolling and pre-deformation with the same rolling direction and the deformation amount of 0-8%, and is subjected to natural aging or artificial aging treatment, wherein the thickness of the pre-deformed aluminum alloy plate blank ranges from 2mm to 30 mm; and then cutting and creep age forming are carried out on the aluminum alloy plate blank.
More preferably, the aluminum alloy plate blank is 2195 aluminum alloy.
The solid solution heat treatment and pre-deformation treatment process of the 2195 aluminum alloy plate blank specifically comprises the following steps: heating to 510 ℃, preserving heat for 30 minutes, carrying out water quenching for 5 minutes, moving the furnace for less than 15s, wherein the rolling pre-deformation amount of the 2195 aluminum alloy plate blank is 4%, and the aging mode of the 2195 aluminum alloy plate blank adopts natural aging.
The invention has at least the following beneficial effects:
the invention provides a creep age forming regulation and control method, wherein a plurality of samples with the same outline and size are cut on an aluminum alloy plate blank before the aluminum alloy plate blank is cut, the included angles between the length direction of each sample and the rolling direction of the aluminum alloy plate blank are different, each sample is added into a creep testing machine, a creep tensile or compression test is carried out on each sample, the creep amount of each sample along the length direction is measured in real time, the length direction of the sample with the largest creep amount and the fastest creep speed is taken as the main forming direction of the aluminum alloy plate to be cut for creep age forming, and accordingly the aluminum alloy plate blank is cut and blanked. According to the invention, the creep performance of the aluminum alloy plate blank in each direction (the direction takes the rolling direction of the aluminum alloy plate blank as a relative reference) is firstly tested in the creep testing machine, the optimal forming direction of the aluminum alloy plate blank is determined, and then the aluminum alloy plate blank is cut and blanked, so that the optimal forming direction of the aluminum alloy plate placed on the die is parallel to or coincided with the plane of the curve with the maximum curvature on the die surface, thus the forming limit of the aluminum alloy plate is improved, the aluminum alloy plate can reach a larger curvature at a higher speed, the load, time or temperature required by reaching the target forming curvature can be further reduced, and the success rate and efficiency of creep forming are improved.
In addition, as the limit forming amount of the aluminum alloy plate is increased, the springback amount in the forming process is correspondingly reduced, and the shape and size errors of the finally obtained component relative to the target component are also reduced, namely the method can improve the forming precision of creep forming.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic view of three sample cutting directions in accordance with a preferred embodiment of the present invention;
FIG. 2 is a graph of the amount of creep in the creep testing machine for three test specimens in accordance with a preferred embodiment of the present invention as a function of time;
fig. 3 is a schematic view showing the placement of the aluminum alloy sheet on the die with the direction of sample three as the main forming direction in the preferred embodiment of the present invention.
In the figure: 1-sample one, 2-sample two, 3-sample three, 4-aluminum alloy plate blank, 5-die, 6-die profile and 7-aluminum alloy plate.
Detailed Description
Embodiments of the invention will be described in detail below with reference to the drawings, but the invention can be implemented in many different ways, which are defined and covered by the claims.
Referring to fig. 1-2, a creep age forming control method, specifically, in addition to controlling at least one of aging time, aging temperature, loading load and pre-deformation in the creep age forming process, considers and controls the angle between the rolling direction of an aluminum alloy plate and the plane of the curve with the maximum curvature on the curved surface member, i.e. the mold surface, in the creep age forming process, so as to obtain the best cutting and blanking mode before creep age forming and/or the best creep age forming mold design mode, and further improve the forming efficiency of the aluminum alloy member during creep forming and/or the aluminum alloy member after creep forming has ideal product performance.
The investigation and regulation of the factor of the included angle between the rolling direction of the aluminum alloy plate and the plane of the curve with the maximum curvature on the die profile in the creep aging forming process specifically comprises the following steps:
s1) cutting three samples with the same size and contour on an aluminum alloy plate blank to be formed, wherein the size and contour of the three samples are the same as those of a standard plate-shaped sample, and the included angles between the length direction of each sample and the rolling direction L of the aluminum alloy plate blank are different;
referring to fig. 1, in the three samples of the present embodiment, an included angle between the length direction of one sample and the rolling direction L of the aluminum alloy plate blank 4 is equal to 0 °, which is defined as sample one 1 in the present embodiment; the included angle between the length direction of one sample and the rolling direction of the aluminum alloy plate blank is equal to 45 degrees, and the included angle is defined as a second sample 2 in the embodiment; the angle between the length direction of the further test piece and the rolling direction of the aluminium alloy sheet blank is equal to 90 °, defined in this example as test piece three 3.
S2) clamping the three samples into a creep testing machine, and preparing to perform a creep tensile test on each sample, wherein the tensile direction of the samples is the same as the length direction of the samples;
s3), under the same conditions of load, temperature and loading time, in the embodiment, the creep testing machine applies 160MPa of tensile load to three samples, the three samples are all kept at the creep temperature of 180 ℃ for 20 hours, the creep tensile test is carried out on each sample, and the creep amount of each sample along the length direction is measured in real time in the test process;
s4), taking the length direction of the sample with the largest creep amount and the fastest creep speed as the main forming direction M of the aluminum alloy plate to be cut for creep age forming, and accordingly cutting the aluminum alloy plate blank, wherein the main forming direction of the aluminum alloy plate is parallel to the plane of the curve with the largest curvature on the formed curved surface member, namely the mould profile. The curved surface component is the melon lamella form wallboard of two-way bend or the half-cylinder shape wallboard of one-way bend, if the curved surface component is the half-cylinder shape wallboard of one-way bend, the main direction of formation of aluminum alloy plate is the radial direction of half-cylinder shape wallboard.
In this embodiment, the aluminum alloy plate blank is made of 2195 aluminum alloy, and the chemical composition thereof is shown in table 1.
TABLE 1
The 2195 aluminum alloy plate blank is subjected to solution heat treatment, heated to 510 ℃ and kept warm for 30 minutes, water quenched for 5 minutes, furnace moving time is less than 15s, pre-deformation amount of 4% is applied through rolling, natural aging is carried out to be in a basically stable state, and the thickness of the pre-deformed aluminum alloy plate blank is 2 mm. The 2195 aluminium alloy after heat treatment has good comprehensive performance and is a common aviation material.
Referring to fig. 2, it can be seen that the three specimens will undergo slow creep deformation under stress and aging temperatures, with specimen length increasing over time. Solute atoms such as copper, lithium and the like which are over-dissolved in aluminum matrix can be precipitated in vacancies such as dislocation or grain boundary and the like at the aging temperature to generate T1And the precipitated phases such as theta' and the like increase the strength of the material, and as can be seen from fig. 2, the 2195 aluminum alloy plate blank selected in the embodiment has stronger creep anisotropy, and the creep amount and the creep speed of each sample are different along with the difference of the included angle between the length direction and the rolling direction, wherein the creep amount and the creep speed of the first sample are the minimum, and the creep amount and the creep speed of the third sample are the maximum. As can be seen from FIG. 2, if the lengthwise direction of sample three is selected as the main forming direction, it takes only 90 minutes to formThe molding amount which can be achieved only in 20 hours when the longitudinal direction of the first sample is the main molding direction can be achieved. For both samples three, at the same creep time of 20 hours, the amount of creep was 0.17%, whereas the amount of creep for sample one was only 0.08%, and the amount of creep for sample three was more than twice that of sample one. Therefore, the length direction of the sample three is selected as the optimal forming direction, that is, the 90 ° direction is the optimal forming direction of the aluminum alloy plate blank in the embodiment, when the aluminum alloy plate blank is cut, the aluminum alloy plate blank is cut according to the principle that the length direction of a straight line corresponding to a curve of the maximum curvature on a die profile or a curved surface member on the straight aluminum alloy plate blank and the rolling direction form 90 °, so that the cut aluminum alloy plate can exert the optimal creep performance in the creep age forming process, that is, the direction is selected as the main forming direction, so that the load, time or temperature required for reaching the target forming curvature can be reduced, the success rate of creep forming can be improved by reducing the load and the temperature, and the creep forming efficiency can be improved.
Referring to fig. 3, when the direction of the sample three is taken as the main forming direction, the aluminum alloy plate 7 obtained by cutting the aluminum alloy plate blank 4 is placed on the die 5, the die 5 shown in fig. 3 is used for processing a semi-cylindrical wall member, the diameter of the die profile 6 is 4m, the axial length is equal to 2m, the semi-cylindrical wall surface is a one-way bending member, the radial direction of the die profile is the main forming direction, and the length direction (i.e., the left-right direction in fig. 3) of the aluminum alloy plate 7 is placed along the radial direction of the die profile, and the direction is perpendicular to the rolling direction of the aluminum alloy plate blank. After placing an aluminum alloy plate, paving a vacuum film on the aluminum alloy plate, sealing the aluminum alloy plate by using a high-temperature adhesive tape, vacuumizing the aluminum alloy plate and a mold together to an autoclave for actual creep aging forming, wherein in the embodiment, the aging temperature in the autoclave is 180 ℃, the aging temperature is the same as the creep test temperature in a creep test machine, the pressure holding time is 4 hours, which is less than the creep test time of a sample in the creep test machine, in the embodiment, the air pressure applied to the aluminum alloy plate in the autoclave is 1MPa, the pressure value of 1MPa is calculated by simulation software, specifically, the relation between the load and the creep variable of the sample obtained by the creep test of the creep test machine is firstly introduced into finite element simulation software (such as MARC finite element simulation software), and the simulation software calculates the required applied air pressure in the autoclave according to the size and the structure of a target component in combination with a series of creep constitutive equations, further, actual creep age forming was performed in an autoclave.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. A creep age forming regulation and control method is characterized in that besides at least one factor of aging time, aging temperature, loading load and pre-deformation in the creep age forming process, the factor of an included angle between the rolling direction of an aluminum alloy plate and a plane of a curve with the maximum curvature on a formed curved surface member, namely a mold profile, in the creep age forming process is considered and regulated, so that the optimal cutting blanking mode before creep age forming and/or the optimal design mode of a creep age forming mold are/is obtained, and the forming efficiency of the aluminum alloy member in the creep forming process is improved and/or the aluminum alloy member after the creep forming has ideal product performance;
the investigation and regulation of the factor of the included angle between the rolling direction of the aluminum alloy plate and the plane of the curve with the maximum curvature on the die profile in the creep aging forming process specifically comprises the following steps:
s1) cutting a plurality of samples with the same size and contour on the aluminum alloy plate blank to be formed, wherein included angles between the length direction of each sample and the rolling direction of the aluminum alloy plate blank are different;
s2) clamping each sample into a creep testing machine, and preparing to perform creep tensile or compression tests on each sample, wherein the tensile or compression direction of the sample is kept the same as the length direction of the sample;
s3) carrying out creep tensile or compression test on each sample under the same conditions of load, temperature and loading time, and measuring the creep amount of each sample along the length direction in real time in the test process;
s4) taking the length direction of the sample with the largest creep amount and the fastest creep speed as the main forming direction M of the aluminum alloy plate to be cut for creep age forming, and accordingly cutting the aluminum alloy plate blank, wherein the main forming direction M of the aluminum alloy plate refers to the direction parallel to the plane of the curve with the largest curvature on the molded curved surface member, namely the mold profile;
the curved surface component is a two-way bent melon petal-shaped wallboard or a one-way bent semi-cylindrical wallboard.
2. The method for controlling creep age forming according to claim 1, wherein an angle between a length direction of one of the plurality of samples and a rolling direction L of the aluminum alloy plate blank is equal to 0 °, an angle between a length direction of the other one of the plurality of samples and a rolling direction L of the aluminum alloy plate blank is equal to 90 °, and an angle between a length direction of at least one of the plurality of samples and a rolling direction of the aluminum alloy plate blank is greater than 0 ° and less than 90 °.
3. The method for controlling creep age forming according to claim 2, wherein the included angle between the length direction and the rolling direction of the aluminum alloy plate blank is greater than 0 ° and less than 90 °, the included angle between the length direction of one sample and the rolling direction of the aluminum alloy plate blank is equal to 45 °, and the included angles between the length direction of the other two samples and the rolling direction of the aluminum alloy plate blank are respectively equal to 30 ° and 60 °.
4. The creep aging forming control method according to claim 1, wherein the creep test temperature of the sample in the creep test machine is equal to the creep aging temperature to be performed on the aluminum alloy sheet in the actual autoclave, and the creep test time of the sample in the creep test machine is greater than or equal to the creep aging time to be performed on the aluminum alloy sheet in the actual autoclave; the change relation between the creep test load of the sample in the creep test machine and the creep quantity of the sample is used for providing the change relation to a finite element simulation system as a parameter for simulating and calculating the required applied air pressure in the autoclave.
5. A creep age forming control method according to any one of claims 1 to 4, wherein the aluminum alloy plate blank is an aluminum alloy plate blank which is subjected to solution heat treatment, rolling and pre-deformation with the same rolling direction and deformation amount of 0-8%, and natural aging or artificial aging treatment, wherein the thickness of the aluminum alloy plate blank subjected to pre-deformation ranges from 2mm to 30 mm; and then cutting and creep age forming are carried out on the aluminum alloy plate blank.
6. The method for regulating creep age forming of claim 5, wherein the aluminum alloy plate blank is 2195 aluminum alloy.
7. The method for regulating creep age forming of claim 5, wherein the solution heat treatment and pre-deformation treatment process of the 2195 aluminum alloy plate blank specifically comprises the following steps: heating to 510 ℃ and preserving heat for 30 minutes, quenching with water for 5 minutes, wherein the rolling pre-deformation amount of the 2195 aluminum alloy plate blank is 4%, and the aging mode of the 2195 aluminum alloy plate blank adopts natural aging.
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| US6264771B1 (en) * | 1995-02-03 | 2001-07-24 | Daimler-Benz Aerospace Ag | Process for forming a plate-like component |
| CN103691793A (en) * | 2013-12-20 | 2014-04-02 | 中南大学 | Age hardenable aluminum alloy integral panel one-step forming method based on autoclave |
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| GB0229434D0 (en) * | 2002-12-18 | 2003-01-22 | Bae Systems Plc | Aircraft component manufacturing tool and method |
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| US6264771B1 (en) * | 1995-02-03 | 2001-07-24 | Daimler-Benz Aerospace Ag | Process for forming a plate-like component |
| CN103691793A (en) * | 2013-12-20 | 2014-04-02 | 中南大学 | Age hardenable aluminum alloy integral panel one-step forming method based on autoclave |
| CN104190777A (en) * | 2014-09-26 | 2014-12-10 | 中南大学 | One-step shaping method for non-aging reinforced aluminum alloy whole wallboard based on autoclave |
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