CN113065210B - Method for controlling space envelope forming buckling deformation of thin-wall component - Google Patents

Method for controlling space envelope forming buckling deformation of thin-wall component Download PDF

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CN113065210B
CN113065210B CN202110350914.0A CN202110350914A CN113065210B CN 113065210 B CN113065210 B CN 113065210B CN 202110350914 A CN202110350914 A CN 202110350914A CN 113065210 B CN113065210 B CN 113065210B
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韩星会
华林
胡亚雄
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Wuhan University of Technology WUT
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Abstract

The invention relates to a method for controlling space envelope forming buckling deformation of a thin-wall component, which comprises the following steps: s1, establishing a rectangular coordinate system; s2 envelope center O of envelope model1Envelope mode envelope center O on z-axis1The distance between the coordinate and the origin O is H; s3, carrying out envelope mold conical point offset; s4, designing a main body part of an envelope mould; s5, designing the front end part of the envelope model; s6, optimizing process parameters; s7, controlling the space envelope forming buckling deformation of the thin-wall component; the plastic deformation of reduced wall thickness and increased diameter occurs in the space envelope forming process of the thin-wall component, the contact area of the main body part of the envelope die and the blank is arranged on one side of the central shaft, and the contact area of the front end part of the envelope die and the blank is arranged on the other side of the central shaft, so that the space envelope forming buckling deformation control of the thin-wall component is realized. The method can realize the accurate control of the space envelope forming buckling deformation of the thin-wall component, thereby improving the space envelope forming precision and the yield of the thin-wall component.

Description

Method for controlling space envelope forming buckling deformation of thin-wall component
Technical Field
The invention relates to the field of manufacturing of thin-wall components, in particular to a method for controlling space envelope forming buckling deformation of a thin-wall component.
Background
The thin-wall component is a key part of high-end equipment and is widely applied to airplanes, spacecrafts, ships and the like. The thin-wall component has poor service conditions and high assembly requirements, which puts strict requirements on the mechanical property and the precision of the thin-wall component. At present, the main manufacturing method of the thin-wall component is a machining method, the high-precision thin-wall component can be manufactured by the method, but the streamline of the thin-wall component is damaged, and the performance of the thin-wall component is difficult to guarantee.
The space envelope forming method is a new continuous local plastic forming method and has the advantages of small forming load, large forming flexibility, high forming efficiency and the like. The thin-wall component is manufactured by a space envelope forming method, the streamline of the thin-wall component is kept intact, and the mechanical property is excellent. However, the thin-wall component has small thickness, and the defect of warping deformation is easily generated in the space envelope forming process, so that the forming precision and the yield of the thin-wall component are reduced.
Disclosure of Invention
The invention aims to provide a method for controlling the buckling deformation of the thin-wall component during the space envelope forming process, which can control the buckling deformation of the thin-wall component during the space envelope forming process.
The technical scheme adopted by the invention for solving the technical problems is as follows: a method for controlling the space envelope forming buckling deformation of a thin-wall component is constructed, and comprises the following steps:
s1, establishing a rectangular coordinate system, wherein an xOy plane of the rectangular coordinate system is superposed with the upper surface of the component bottom plate, a central axis of the component is a z axis of the rectangular coordinate system, and an intersection point of the xOy plane and the z axis is a coordinate origin O;
s2, enveloping the center O of the mould envelope1Envelope mode envelope center O on z-axis1The distance between the coordinate and the origin O is H;
s3, carrying out envelope mold conical point offset; the axial section of the envelope model is coincident with the xOz plane of the rectangular coordinate system, after the envelope center of the envelope model is adjusted, the cone point of the envelope model is offset, the main body part of the envelope model is positioned at one side of an x positive half shaft, the front end part of the envelope model is positioned at one side of an x negative half shaft, and the cone point O of the envelope model is positioned at one side of an x negative half shaft2At x negative semi-axis and enveloping mode cone point O2The distance between the coordinate and the origin O is e;
s4, designing a main body part of an envelope mould; during the space envelope forming process, the envelope mould and the member are in line contact on the axial section of the envelope mould and are completely matched, and the coordinate (x, y, z) of any point A on the upper surface of the member corresponds to the surface point A of the main body part of the envelope mould1Point A1Coordinate (x)1,y1,z1) The calculation formula is shown in equation (1):
Figure BDA0003002345540000021
in the formula, theta is an included angle between a component upper surface point A and an x-axis, gamma is an included angle between an envelope mode axis and a z-axis, and alpha is an included angle between the component upper surface point A and the z-axis;
s5, designing the front end part of the envelope model; the front end part of the envelope mould is an extension of the main body part of the envelope mould, the shape of the front end part of the envelope mould is a cone, and any point A on the surface of the cone is2Coordinates of (2)(x2,y2,z2) As shown in equation (2):
Figure BDA0003002345540000022
in the formula, beta is any angle, and beta belongs to [0,2 pi ];
s6, optimizing process parameters: the ratio delta h of the feeding speed v of the lower die to the rotating speed n of the enveloping die meets the equation (3), so that the enveloping die is fully contacted with the component in the space enveloping forming process, and the forming load is in a reasonable range;
0.5≤Δh≤1 (3)
s7, controlling the space envelope forming buckling deformation of the thin-wall component; in the initial stage of space envelope forming of the thin-wall component, an envelope die moves in a circular track at a rotating speed n, a lower die approaches to the envelope die at a speed v, the main body part of the envelope die is arranged on one side of a central shaft, and the front end part of the envelope die is arranged on the other side of the central shaft; the plastic deformation of reduced wall thickness and increased diameter occurs in the space envelope forming process of the thin-wall component, the contact area of the main body part of the envelope die and the blank is arranged on one side of the central shaft, and the contact area of the front end part of the envelope die and the blank is arranged on the other side of the central shaft, so that the space envelope forming buckling deformation control of the thin-wall component is realized.
In the above scheme, the relationship between the envelope mode cone point offset distance e and the envelope mode envelope center point adjustment distance H is as shown in equation (4):
e＝H tanγ (4)。
in the scheme, when the coordinate of the surface point A on the component is (0,0,0), the included angle theta is an arbitrary value in the range of [0,2 pi ]; when the coordinates of the member upper surface point a are not (0,0,0), the calculation formula of the angle θ between the member upper surface point a and the x-axis is as shown in equation (5):
Figure BDA0003002345540000023
in the above scheme, the calculation formula of the included angle α between the surface point a on the component and the z-axis is shown in equation (6):
Figure BDA0003002345540000031
the implementation of the method for controlling the space envelope forming buckling deformation of the thin-wall component has the following beneficial effects:
(1) according to the invention, the envelope center position of the envelope die is adjusted, the envelope die is biased, the main part and the front end part of the envelope die are designed, process parameters are optimized, the contact of the envelope die and a member on two sides of a central shaft is increased, the accurate control of the space envelope forming buckling deformation of the thin-wall member can be realized, and the space envelope forming precision and the yield of the thin-wall member are further improved.
(2) The invention can realize the high-efficiency control of the space envelope forming buckling deformation of the thin-wall component, thereby improving the design efficiency of the space envelope forming process of the thin-wall component, reducing the product development cycle and reducing the production cost.
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The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a schematic diagram of a thin-wall component space envelope forming buckling deformation control method;
FIG. 2 is an axial cross-sectional view of a thin-walled component;
FIG. 3 is a schematic axial cross-sectional view of the main portion of the overmold;
FIG. 4 is a schematic diagram of an initial state of space envelope forming of a thin-wall component;
FIG. 5 is a schematic diagram of the result of space envelope forming of a thin-wall member subjected to buckling deformation control;
FIG. 6 is a schematic representation of the results of the spatial envelope formation of a thin-walled component without buckling deformation control.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
As shown in FIG. 1, the method for controlling the space envelope forming buckling deformation of the thin-wall component comprises the following steps:
and S1, determining the control principle of the space envelope forming buckling deformation of the thin-wall component (as shown in figure 1). Wherein 1 is a main body part of the envelope die, 2 is a front end part of the envelope die, 3 is a member, and 4 is a lower die. According to the geometric shape of the enveloping die, under a specific rectangular coordinate system, the enveloping die is adjusted to envelop the central position, the enveloping die is biased, the main part and the front end part of the enveloping die are designed, technological parameters are optimized, the contact between the enveloping die and the member on two sides of the central shaft is increased, and the buckling deformation of the thin-wall member in the space enveloping forming process is controlled.
And S2, establishing a rectangular coordinate system. The geometry and dimensions of the component are shown in FIG. 1, the component base plate outer diameter d1100mm, thickness h of the base plate of the member13mm, inner diameter d of member rib plate270mm, height h of member rib plate2The thickness a of the member rib plate is 5mm and 3 mm. The xOy plane of the rectangular coordinate system coincides with the upper surface of the base plate of the component, the central axis of the component is the z-axis of the rectangular coordinate system, and the intersection point of the xOy plane and the z-axis is the origin of coordinates O, as shown in fig. 2.
S3 envelope center O of envelope model1Envelope mode envelope center O on z-axis1And the distance H from the coordinate origin O is 57.15mm, and the included angle gamma between the envelope model axis and the z axis is 5 degrees, as shown in figure 1.
And S4, envelope modulus offset. The axial section of the envelope model is coincident with the xOz plane of the rectangular coordinate system, after the envelope center of the envelope model is adjusted, the envelope model is biased, the main body part of the envelope model is positioned at one side of an x positive half shaft, the front end part of the envelope model is positioned at one side of an x negative half shaft, and the cone point O of the envelope model2Located at the negative x half axis, and calculating the envelope mode cone point O according to equation (4)2And the origin O of coordinates, as shown in fig. 1, by a distance e of 5 mm.
And S5, enveloping the main body part design. During the space envelope forming process, the envelope mould and the member are in line contact on the axial section of the envelope mould and are completely matched, the coordinate of a point A on the upper surface of the member is (0,35,5), and the point A corresponds to a surface point A on the main body part of the envelope mould1(x1,y1,z1) Calculating the point A according to equation (1)1Is (0,39.41,8.25), the envelope model body part is established as shown in fig. 3.
Figure BDA0003002345540000041
In the formula, the included angle θ between the upper surface point a of the member and the x-axis is calculated according to equation (5), the included angle γ between the envelope axis and the z-axis is 5 °, and the included angle α between the upper surface point a of the member and the z-axis is calculated according to equation (6).
And S6, designing the front end part of the envelope model. The envelope front portion is an extension of the envelope main body portion, the envelope front portion is conical in shape, and the coordinates (3.15,1.82,0.10), z, of a point on the envelope front portion surface are calculated according to equation (2)2∈[-0.22,0.22]。
Figure BDA0003002345540000042
In the formula, angle
Figure BDA0003002345540000043
And S7, optimizing process parameters. The ratio delta h of the feeding speed v of the lower die to the rotating speed n of the enveloping die to 4rad/s is 0.5, equation (3) is satisfied, and sufficient contact between the enveloping die and the component is ensured in the space enveloping forming process, and simultaneously the forming load is in a reasonable range.
0.25≤Δh≤0.75 (3)
And S8, controlling the space envelope forming buckling deformation of the thin-wall component. The initial stage of space envelope forming of the thin-walled member is shown in fig. 4, wherein 5 is a blank, the diameter d of the blank090mm, blank thickness h0The enveloping die moves in a circular track at a rotating speed n, and the lower die approaches to the enveloping die at a speed v. The main part of the envelope mould is arranged on one side of the central shaft, and the front part of the envelope mould is arranged on the other side of the central shaft; the plastic deformation with reduced wall thickness and increased diameter occurs in the space enveloping forming process of the thin-wall component, the contact area of the main body part of the enveloping die and the blank is arranged at one side of the central shaft, and the contact area of the front end part of the enveloping die and the blank is arranged at the other side of the central shaft, thereby realizing the control of the space enveloping forming buckling deformation of the thin-wall component and the maximum buckling amountw10.15mm as shown in fig. 5. Comparing the maximum warpage amount w without warpage control2When the maximum warp deformation is controlled, the maximum warp deformation is reduced by 72% as shown in fig. 6, which is 0.53 mm.
In the above step, the envelope mold conical point offset distance e is calculated to be 5mm according to equation (4).
e＝H tanγ (4)
In the above step, the included angle θ between the member upper surface point a and the x-axis is calculated to be 120 ° according to equation (5).
Figure BDA0003002345540000051
In the above step, the included angle α between the member upper surface point a and the z-axis is calculated to be 72.6 ° according to equation (5).
Figure BDA0003002345540000052
While the present invention has been described with reference to the embodiments, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and those skilled in the art can make various changes and modifications without departing from the spirit and the scope of the present invention.

Claims (4)

1. A method for controlling the space envelope forming buckling deformation of a thin-wall component is characterized by comprising the following steps:
s1, establishing a rectangular coordinate system, wherein an xOy plane of the rectangular coordinate system is superposed with the upper surface of the component bottom plate, a central axis of the component is a z axis of the rectangular coordinate system, and an intersection point of the xOy plane and the z axis is a coordinate origin O;
s2 envelope center O of envelope model1Envelope mode envelope center O on z-axis1The distance between the coordinate and the origin O is H;
s3 envelope mode cone point offset(ii) a The axial section of the envelope model is coincident with the xOz plane of the rectangular coordinate system, after the envelope center of the envelope model is adjusted, the cone point of the envelope model is offset, the main body part of the envelope model is positioned at one side of an x positive half shaft, the front end part of the envelope model is positioned at one side of an x negative half shaft, and the cone point O of the envelope model is positioned at one side of an x negative half shaft2At x negative semi-axis and enveloping mode cone point O2The distance between the coordinate and the origin O is e;
s4, designing a main body part of an envelope mould; during the space envelope forming process, the envelope mould and the member are in line contact on the axial section of the envelope mould and are completely matched, and the coordinate (x, y, z) of any point A on the upper surface of the member corresponds to the surface point A of the main body part of the envelope mould1Point A1Coordinate (x)1,y1,z1) The calculation formula is shown in equation (1):
Figure FDA0003002345530000011
in the formula, theta is an included angle between a component upper surface point A and an x-axis, gamma is an included angle between an envelope mode axis and a z-axis, and alpha is an included angle between the component upper surface point A and the z-axis;
s5, designing the front end part of the envelope model; the front end part of the envelope mould is an extension of the main body part of the envelope mould, the shape of the front end part of the envelope mould is a cone, and any point A on the surface of the cone is2Coordinate (x) of2,y2,z2) As shown in equation (2):
Figure FDA0003002345530000012
in the formula, beta is any angle, and beta belongs to [0,2 pi ];
s6, optimizing process parameters: the ratio delta h of the feeding speed v of the lower die to the rotating speed n of the enveloping die meets the equation (3), so that the enveloping die is fully contacted with the member in the space enveloping forming process, and the forming load is in a reasonable range;
0.5≤Δh≤1 (3)
s7, controlling the space envelope forming buckling deformation of the thin-wall component; in the initial stage of space envelope forming of the thin-wall component, an envelope die moves in a circular track at a rotating speed n, a lower die approaches the envelope die at a speed v, the main body part of the envelope die is arranged on one side of a central shaft, and the front end part of the envelope die is arranged on the other side of the central shaft; the plastic deformation of reduced wall thickness and increased diameter occurs in the space envelope forming process of the thin-wall component, the contact area of the main body part of the envelope die and the blank is arranged on one side of the central shaft, and the contact area of the front end part of the envelope die and the blank is arranged on the other side of the central shaft, so that the space envelope forming buckling deformation control of the thin-wall component is realized.
2. The method for controlling the spatial envelope forming buckling deformation of the thin-wall component according to claim 1, wherein the relationship between the envelope mold conical point offset distance e and the envelope mold envelope center point adjustment distance H is as shown in equation (4):
e＝H tanγ (4)。
3. the method for controlling the spatial envelope forming buckling deformation of the thin-wall component as claimed in claim 1, wherein when the coordinates of the surface point A on the component are (0,0,0), the included angle theta is any value within the range of [0,2 pi ]; when the coordinates of the member upper surface point a are not (0,0,0), the calculation formula of the angle θ between the member upper surface point a and the x-axis is as shown in equation (5):
Figure FDA0003002345530000021
4. the method for controlling the space envelope forming buckling deformation of the thin-wall component according to claim 1, wherein the calculation formula of the included angle α between the component upper surface point A and the z axis is shown in equation (6):
Figure FDA0003002345530000022
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CN110695355A (en) * 2019-10-09 2020-01-17 中国航空工业集团公司洛阳电光设备研究所 Process method for controlling buckling deformation of aluminum alloy thin-wall part in 3D printing process
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