WO2022100689A1 - 大曲率混杂结构零件的外型控制方法 - Google Patents

大曲率混杂结构零件的外型控制方法 Download PDF

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Publication number
WO2022100689A1
WO2022100689A1 PCT/CN2021/130295 CN2021130295W WO2022100689A1 WO 2022100689 A1 WO2022100689 A1 WO 2022100689A1 CN 2021130295 W CN2021130295 W CN 2021130295W WO 2022100689 A1 WO2022100689 A1 WO 2022100689A1
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Prior art keywords
tooling
curvature
profile
appearance
forming
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PCT/CN2021/130295
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English (en)
French (fr)
Inventor
陈秋云
倪永佳
张君红
徐少晨
晏冬秀
卫亨亮
李力
董柳杉
王星童
孙凯
蔡文侃
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上海飞机制造有限公司
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Publication of WO2022100689A1 publication Critical patent/WO2022100689A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3097—Cosmonautical vehicles; Rockets

Definitions

  • the present application relates to the field of composite material forming, for example, to a method for controlling the appearance of large-curvature hybrid structural parts.
  • the leading edge parts In the field of aviation manufacturing, the leading edge parts generally adopt a U-shaped large curvature structure. Among them, appearance control is one of the biggest technical difficulties in the manufacturing process of large-curvature structural parts.
  • Patent Document 1 a manufacturing process method for a large-curvature full-profile thin-walled plate is provided, which includes the following steps: (1) rough machining of the outer cavity profile; (2) rough machining of the inner cavity profile; (3) Natural failure; (4) Flattening to eliminate deformation, and expanding and reaming process holes; (5) Semi-finishing and finishing of inner cavity surface; (6) Filling gypsum; (7) Semi-finishing of outer cavity surface Finishing; (8) process flow such as fitter polishing.
  • Patent Document 1 CN103639655A
  • the forming of hybrid structural parts adopts the method of female mold forming, but because the deformation trend of the parts is not clear, the shape requirements of the parts can only be achieved by repairing the mold and repeating iteratively. This method has high cost, long cycle, and great uncertainty in repairing the mold, which leads to the part's appearance exceeding the specified appearance requirements.
  • the present application provides a method for controlling the appearance of large-curvature hybrid structural parts.
  • adjustable tooling With the help of adjustable tooling, the tooling profile of the forming tooling of the large-curvature hybrid structural parts can be adjusted, so that the accurate appearance of the large-curvature hybrid structural parts can be achieved. control.
  • a method for controlling the appearance of a large-curvature hybrid structural part which is used when the large-curvature hybrid structural part is formed by a negative mold forming method, including: a step of analyzing the appearance of the part; The appearance is analyzed; the selection steps of the design parameters of the forming tooling are carried out simulation analysis. According to the simulation analysis results and the characteristics of the parts, the out-of-tolerance area and out-of-tolerance range in the appearance of the above-mentioned large-curvature hybrid structural parts are determined, and the design of the forming tooling is determined.
  • the manufacturing steps of the forming tooling, the above-mentioned forming tooling is manufactured according to the design parameters of the above-mentioned forming tooling, and the position of the tooling profile of the above-mentioned forming tooling and the out-of-tolerance area in the outer shape of the above-mentioned large-curvature hybrid structural part is adjustable. point; the design and manufacturing steps of the adjustable tooling, according to the appearance characteristics and easily deformable areas of the above-mentioned large-curvature hybrid structural parts, design and manufacture the adjustable tooling; the part forming step, according to the above-mentioned large-curvature hybrid structural parts.
  • the above-mentioned adjustable tooling adjusts the tooling profile of the above-mentioned forming tooling to the theoretical profile of the above-mentioned large-curvature hybrid structural part to be manufactured, and uses the adjusted above-mentioned forming tooling to shape the above-mentioned large-curvature hybrid structural part; and the shape of the part.
  • the control step is to detect and analyze the appearance of the above-mentioned large-curvature hybrid structural parts obtained by using the adjusted above-mentioned forming tooling with the above-mentioned theoretical profile to obtain an out-of-tolerance area and an out-of-tolerance range, and use the above-mentioned adjustable tooling to adjust the above-mentioned tooling type.
  • Adjust the adjustable points on the surface corresponding to the found out-of-tolerance area use the adjusted forming tool to form the above-mentioned large-curvature hybrid structural parts, and test the appearance of the manufactured above-mentioned large-curvature hybrid structural parts. Analyze and adjust the tooling profile of the above-mentioned forming tool, and iterate repeatedly until the tooling profile of the forming tool that fully meets the appearance requirements of the above-mentioned large-curvature hybrid structural parts is obtained.
  • FIG. 1 is a flow chart showing the appearance control method of the large-curvature hybrid structural part of the present application.
  • Fig. 2 is a perspective view showing a part to be manufactured of the embodiment.
  • FIG. 3 is a schematic diagram showing the adjustable area of the forming tool of the embodiment.
  • FIG. 4 is a schematic diagram showing the structure of the adjustable jig of the embodiment.
  • FIG. 5 is a schematic structural diagram of a shape control device of a large-curvature hybrid structural part provided by the application.
  • FIG. 6 is a schematic structural diagram of a device provided by the application.
  • the method for controlling the appearance of a large-curvature hybrid structural part in this embodiment is suitable for forming a large-curvature hybrid structural part (hereinafter referred to as a part) bonded by metal and composite material by using the female mold forming method.
  • a part large-curvature hybrid structural part
  • the tooling profile of the forming tooling of the large-curvature hybrid structural parts is adjusted, so as to realize the precise control of the appearance of the parts.
  • Step S1 in the method for controlling the appearance of a large-curvature hybrid structural part in this embodiment, analyze the appearance characteristics of the part to be manufactured.
  • Step S2 carry out a simulation analysis, determine the possible out-of-tolerance area and out-of-tolerance range in the appearance of the part, and determine the design parameters of the forming tool according to the simulation analysis result and the characteristics of the part.
  • the thickness of the forming tool is selected in such a way that it has the rigidity required for forming the part, and has a certain degree of adjustability.
  • Performing a simulation analysis may be performing a simulation analysis on the appearance of the part to be manufactured.
  • Step S3 Manufacture the forming tool according to the design parameters of the forming tool, and set an adjustable point at the position of the tool profile of the forming tool corresponding to the possible out-of-tolerance area in the appearance of the part.
  • Step S4 designing and manufacturing adjustable tooling according to the appearance characteristics and easily deformable area of the part.
  • the adjustable range should meet the three-dimensional adjustable requirements, and the material of the adjustable tooling should be selected according to the adjustable range.
  • the adjustable tooling should meet the requirements of strong operability and be suitable for the use of testing equipment such as laser trackers.
  • Step S5 according to the appearance of the part, adjust the tooling profile of the forming tooling to the theoretical profile required by the part to be manufactured by using the adjustable tooling, and use the adjusted forming tooling to shape the part.
  • Step S6 Detecting and analyzing the appearance of the part formed by using the adjusted forming tool with the theoretical profile to obtain the out-of-tolerance area and out-of-tolerance range.
  • Step S7 using the adjustable tooling to adjust the adjustable point of the tooling profile corresponding to the obtained out-of-tolerance area, and using the adjusted forming tooling to shape the part again.
  • Step S8 Detect the appearance of the obtained parts, analyze the out-of-tolerance area and out-of-tolerance range, and determine whether the appearance requirements are met.
  • the adjustment of the forming tool is ended, and the ideal tooling profile of the forming tool is obtained (step S9).
  • step S8: No return to step S7, adjust the tooling surface, and use the adjusted molding tool to shape the part again until the part that fully meets the appearance requirements of the part is obtained.
  • the tooling profile of the forming tooling is Detect the appearance of the obtained parts, analyze the out-of-tolerance area and out-of-tolerance range, and determine whether the appearance requirements are met.
  • the part forming step also includes a first detection and judgment step, that is, using a laser tracker to detect the tooling profile of the adjusted forming tool, and judging whether the tooling profile of the forming tool is adjusted to a theoretical profile.
  • a first detection and judgment step that is, using a laser tracker to detect the tooling profile of the adjusted forming tool, and judging whether the tooling profile of the forming tool is adjusted to a theoretical profile.
  • the step of controlling the appearance of the part also includes a second detection and judgment step, that is, using a laser tracker to detect the tooling profile of the adjusted forming tool, and judging whether the tooling surface of the forming tool is adjusted to a new one Required tooling profile.
  • step S5 and step S7 detection equipment such as a laser tracker can be used to detect the tooling profile of the forming tool to determine whether the tooling profile of the forming tool is adjusted to a theoretical profile or a newly required tooling profile .
  • FIG. 2 is a perspective view showing a part to be manufactured according to the embodiment
  • FIG. 3 is a schematic view showing the adjustable area of the forming tool of the embodiment
  • FIG. 4 is a schematic view showing the structure of the adjustable tool according to the embodiment.
  • the part 1 shown in FIG. 2 is a large-curvature hybrid structural part in which metal and composite materials are glued, and can be manufactured by using negative molding.
  • a method of controlling the appearance of the part during the manufacturing process will be described.
  • the appearance characteristics of the part 1 to be manufactured are analyzed.
  • the thickness of the forming tool 2 is selected so as to have the rigidity required for forming the part, and to have a certain degree of adjustability.
  • the forming tool 2 is manufactured according to the design parameters, and, as shown in FIG. 3 , an adjustable area and an adjustable point are set on the tool profile of the forming tool 2 at the position corresponding to the possible out-of-tolerance area in the appearance of the part 1 .
  • the number of adjustable points is set according to the degree to which the part 1 may be deformed.
  • Adjustable tooling 3 is designed and manufactured according to the appearance characteristics and easily deformed area of part 1.
  • a plurality of adjustment mechanisms are used in which screw holes are provided in the support frame, and adjustment bolts are inserted through the screw holes. And, one end of the adjustment bolt is connected to the positions of the plurality of adjustable points.
  • the tool profile of the forming tool 2 can be adjusted (pushed in or pulled out) by rotating the adjustment bolt.
  • a holding support 4 is provided to hold and support the adjustable tool 3 .
  • the manufactured adjustable tooling 3 to adjust the tooling profile of the forming tooling 2 to the theoretical profile required by the part 1 to be manufactured, and use detection equipment such as a laser tracker to adjust the tooling of the forming tooling 2
  • the adjusted forming tool 2 uses the adjusted forming tool 2 to form the part again (the forming method is the same as above).
  • Check the appearance of the obtained parts analyze the out-of-tolerance area and out-of-tolerance range, and judge whether the appearance requirements are met. Under the condition that the appearance requirements are met, the adjustment of the forming tool 2 is completed, and the ideal tooling surface of the forming tool is obtained. If the appearance requirements are not met, adjust the tooling surface of the forming tooling 2, use the adjusted forming tooling 2 to shape the part, and iterate repeatedly until the tooling type of the forming tooling that fully meets the appearance requirements of the part is obtained. noodle.
  • a molding jig having a jig profile that fully satisfies the external shape requirements of the part can be obtained, and the molding jig can be repeatedly used in the production of the part.
  • Figure 5 is a schematic structural diagram of a shape control device for a large-curvature hybrid structural part provided by the present application.
  • the apparatus for controlling the appearance of a hybrid structural part with a large curvature provided by the embodiment of the present application can execute the method for controlling the appearance of a hybrid structural part with a large curvature provided in any embodiment of the present application, and the apparatus includes the following modules.
  • the part appearance analysis module 51 is configured to analyze the appearance of the large-curvature hybrid structural part to be manufactured
  • the selection module 52 for the design parameters of the forming tooling is set to perform simulation analysis, and according to the simulation analysis results and the characteristics of the parts, determine the out-of-tolerance area and out-of-tolerance range in the appearance of the large-curvature hybrid structural parts, and determine the design of the forming tooling parameter;
  • the manufacturing module 53 of the forming tool is configured to manufacture the forming tool according to the design parameters of the forming tool, and the out-of-tolerance area of the tool profile of the forming tool corresponds to the outer shape of the large-curvature hybrid structural part
  • the position of the adjustable point is set;
  • the design and manufacture module 54 of the adjustable tooling is configured to design and manufacture the adjustable tooling according to the appearance characteristics and the easily deformable area of the large-curvature hybrid structural parts;
  • the part forming module 55 is configured to use the adjustable tool to adjust the tooling profile of the forming tool to the theoretical profile of the large-curvature hybrid structural part to be manufactured according to the appearance of the large-curvature hybrid structural part , using the adjusted forming tool to form the large curvature hybrid structural part;
  • the control module 56 for the appearance of the part is configured to perform detection and analysis on the appearance of the large-curvature hybrid structural part formed by using the adjusted forming tool with the theoretical profile to obtain an out-of-tolerance area after detection and analysis and the out-of-tolerance range, use the adjustable tooling to adjust the adjustable points of the adjusted tooling profile corresponding to the obtained out-of-tolerance area after detection and analysis, and use the adjusted forming tooling to adjust the large-curvature hybrid
  • the structural parts are formed, the appearance of the manufactured large-curvature hybrid structural parts is detected and analyzed, and the tooling surface of the forming tooling is adjusted, and repeated iterations are performed until the appearance of the large-curvature hybrid structural parts is completely satisfied.
  • the tooling profile of the forming tooling required by the type.
  • the thickness of the forming tool is selected in a manner that has the rigidity required for part forming and has adjustability.
  • the part forming module further includes a first detection and judgment module, which is configured to: use a laser tracker to detect the tooling surface of the adjusted forming tooling, and judge the adjustment Whether the tooling profile of the final forming tool is adjusted to the theoretical profile.
  • control module for the appearance of the part further includes a second detection and judgment module, which is configured to: use a laser tracker to detect the tooling surface of the adjusted forming tooling, and judge the Whether the tooling profile of the forming tool is adjusted to the newly required tooling profile.
  • the appearance control device of the large-curvature hybrid structural part provided by the embodiment of the present application can execute the appearance control method of the large-curvature hybrid structural part provided by any embodiment of the present application, and has corresponding functional modules and effects of the execution method.
  • FIG. 6 is a schematic structural diagram of a device provided by the application.
  • the device includes a processor 60, a memory 61, an input device 62 and an output device 63; the number of processors 60 in the device may be one or more 6, a processor 60 is used as an example; the processor 60, memory 61, input device 62, and output device 63 in the device can be connected through a bus or other means, and the connection through a bus is taken as an example in FIG. 6.
  • the memory 61 can be used to store software programs, computer-executable programs, and modules, such as program instructions/modules corresponding to the method for controlling the appearance of large-curvature hybrid structural parts in the embodiments of the present application.
  • the processor 60 executes various functional applications and data processing of the device by running the software programs, instructions and modules stored in the memory 61, that is, to implement the above-mentioned method.
  • the memory 61 may include a storage program area and a storage data area, wherein the storage program area may store an operating system, an application program required for at least one function; the storage data area may store data created according to the use of the terminal, and the like. Additionally, memory 61 may include high-speed random access memory, and may also include non-volatile memory, such as at least one magnetic disk storage device, flash memory device, or other non-volatile solid-state storage device. In some examples, memory 61 may include memory located remotely from processor 60, which may be connected to the device through a network. Examples of such networks include, but are not limited to, the Internet, an intranet, a local area network, a mobile communication network, and combinations thereof.
  • the input device 62 may be configured to receive input information, etc., and to generate signal input related to user settings and functional control of the device.
  • the output device 63 may include a display device such as a display screen.
  • Embodiments of the present application also provide a storage medium containing computer-executable instructions, the computer-executable instructions being used to execute a shape control method for a large-curvature hybrid structural part when executed by a computer processor.
  • the forming method is used in the case of forming large-curvature hybrid structural parts, wherein the method includes:
  • the step of analyzing the appearance of the part includes: analyzing the appearance of the large-curvature hybrid structural part to be manufactured;
  • the steps of selecting the design parameters of the forming tooling include: carrying out simulation analysis, determining the out-of-tolerance area and out-of-tolerance range in the appearance of the large-curvature hybrid structural part, and determining the design parameters of the forming tooling ;
  • the manufacturing step of the forming tool includes: manufacturing the forming tool according to the design parameters of the forming tool, and the tool profile of the forming tool corresponds to the out-of-tolerance area in the outer shape of the large-curvature hybrid structural part. Position setting adjustable point;
  • the design and manufacturing steps of the adjustable tooling include: designing and manufacturing the adjustable tooling according to the appearance characteristics and the easily deformed area of the large-curvature hybrid structural part;
  • the part forming step includes: according to the appearance of the large-curvature hybrid structural part, using the adjustable tooling to adjust the tooling profile of the forming tool to the theoretical profile of the large-curvature hybrid structural part to be manufactured, forming the high-curvature hybrid structural part using an adjusted forming tool; and
  • the step of controlling the appearance of the part includes: performing detection and analysis on the appearance of the large-curvature hybrid structural part formed by using the adjusted forming tool with the theoretical profile, and obtaining the out-of-tolerance area after detection and analysis and For the out-of-tolerance range, use the adjustable tooling to adjust the adjustable points of the adjusted tooling profile corresponding to the obtained out-of-tolerance area after detection and analysis, and use the adjusted forming tooling to adjust the large-curvature hybrid structure
  • the parts are formed, the appearance of the manufactured large-curvature hybrid structural parts is detected and analyzed, and the tooling surface of the forming tool is adjusted, and repeated iterations are performed until the appearance of the large-curvature hybrid structural parts is fully satisfied.
  • the tooling profile of the required forming tooling is performed by using the adjusted forming tool with the theoretical profile, and obtaining the out-of-tolerance area after detection and analysis and For the out-of-tolerance range.
  • a storage medium containing computer-executable instructions provided by the embodiments of the present application the computer-executable instructions are not limited to the above-mentioned method operations, and can also execute the appearance of the large-curvature hybrid structural parts provided by any embodiment of the present application Related operations in control methods.
  • the storage medium may be a non-transitory storage medium.
  • the present application can be implemented by software and necessary general-purpose hardware, and can also be implemented by hardware.
  • the present application can be embodied in the form of a software product, and the computer software product can be stored in a computer-readable storage medium, such as a floppy disk of a computer, a read-only memory (Read-Only Memory, ROM), a random access memory (Random Access Memory) , RAM), flash memory (FLASH), hard disk or optical disk, etc., including multiple instructions to make a computer device (which may be a personal computer, a server, or a network device, etc.) execute the methods described in the various embodiments of the present application.
  • a computer-readable storage medium such as a floppy disk of a computer, a read-only memory (Read-Only Memory, ROM), a random access memory (Random Access Memory) , RAM), flash memory (FLASH), hard disk or optical disk, etc.
  • the multiple units and modules included are only divided according to the functional logic, but are not limited to the above-mentioned division, as long as the corresponding functions can be realized; in addition, the names of the multiple functional units are also It is only for the convenience of distinguishing from each other, and is not intended to limit the protection scope of the present application.

Abstract

本申请提供大曲率混杂结构零件的外型控制方法，包括：零件外型分析步骤；成型工装设计参数的选择步骤，进行仿真分析，确定零件外型中的超差区域及超差范围，确定成型工装的设计参数；成型工装的制造步骤，制造成型工装，在工装型面的与零件可能的超差区域相应的位置设置可调点；设计及制造可调工装的步骤；零件成型步骤，将工装型面调整成理论型面，对零件进行成型；零件外型的控制步骤，对得到的零件的外型进行检测分析，得到超差区域及超差范围，调整工装型面的与所得到的超差区域相应的可调点，再次对零件进行成型，对制出的零件的外型进行检测分析并对成型工装进行调整，反复迭代直至得到完全满足零件外型要求的工装型面。

Description

大曲率混杂结构零件的外型控制方法
本申请要求在2020年11月12日提交中国专利局、申请号为202011260001.1的中国专利申请的优先权，该申请的全部内容通过引用结合在本申请中。
技术领域
本申请涉及复合材料成型领域，例如涉及一种大曲率混杂结构零件的外型控制方法。
背景技术
在航空制造领域中，前缘类零件一般都采用U型大曲率结构。其中，外型控制是大曲率结构零件制造过程中最大的技术难点之一。
对此，在专利文献1中，提供了一种大曲率全型面薄壁板的制造工艺方法，包括以下步骤：(1)外腔型面粗加工；(2)内腔型面粗加工；(3)自然失效；(4)打平面消除变形，并扩、铰工艺孔；(5)内腔型面半精和精加工；(6)填充石膏；(7)外腔型面半精和精加工；(8)钳工打光等工艺流程。
专利文献1：CN103639655A
上述相关技术借助先进设备来控制相关工艺参数、调整机械加工工艺，以达到零件精确的外型要求。该方法仅适用于金属零件成型。
从减重、抗击鸟撞等角度出发，大曲率混杂结构的构型得到了越来越广泛的应用。但是，由于金属与复合材料的热膨胀系数不一致，导致胶接后零件的变形趋势不易预测，单纯依靠后期机械加工无法保证外型及内部质量。而且，对于金属与复合材料的混杂结构零件的制造，由于金属与复合材料的变形趋势不一致，只依靠机械加工和材料特性很难找到一致的方式，加工过程也会对零件内部质量造成不可逆的损伤。混杂结构零件成型采用阴模成型的方式，但由于零件变形趋势不明确，只能通过修模并反复迭代来达到零件外型要求。该方法成本高、周期长，而且修模具有很大的不确定性，从而导致零件外型超出规定的外型要求。
发明内容
本申请提供一种大曲率混杂结构零件的外型控制方法，借助可调工装，对大曲率混杂结构零件的成型工装的工装型面进行调整，从而能够实现对大曲率混杂结构零件外型的精确控制。
提供了一种大曲率混杂结构零件的外型控制方法，在采用阴模成型方式对大曲率混杂结构零件进行成型时使用，包括：零件外型分析步骤，对待制造的上述大曲率混杂结构零件的外型进行分析；成型工装设计参数的选择步骤，进行仿真分析，根据仿真分析结果及零件特点，确定上述大曲率混杂结构零件的外型中的超差区域及超差范围，确定成型工装的设计参数；成型工装的制造步骤，根据上述成型工装的设计参数制造上述成型工装，在上述成型工装的工装型面的与上述大曲率混杂结构零件的外型中的超差区域相应的位置设置可调点；可调工装的设计及制造步骤，根据上述大曲率混杂结构零件的外型特点和易变形区域，设计并制造可调工装；零件成型步骤，根据上述大曲率混杂结构零件的外型，利用上述可调工装将上述成型工装的工装型面调整成待制造的上述大曲率混杂结构零件的理论型面，使用调整后的上述成型工装对上述大曲率混杂结构零件进行成型；和零件外型的控制步骤，对利用调整后的上述成型工装以上述理论型面成型得到的上述大曲率混杂结构零件的外型进行检测分析，得到超差区域及超差范围，利用上述可调工装对上述工装型面的与所找出的超差区域相应的可调点进行调整，使用调整后的上述成型工装对上述大曲率混杂结构零件进行成型，对制造出的上述大曲率混杂结构零件的外型进行检测分析并对上述成型工装的工装型面进行调整，反复迭代直至得到完全满足上述大曲率混杂结构零件的外型要求的成型工装的工装型面。
附图说明
图1是表示本申请的大曲率混杂结构零件的外型控制方法的流程图。
图2是表示实施例的待制造的零件的立体图。
图3是表示实施例的成型工装的可调区域的示意图。
图4是表示实施例的可调工装的结构的示意图。
图5为本申请提供的一种大曲率混杂结构零件的外型控制装置的结构示意图。
图6为本申请提供的一种设备的结构示意图。
附图标记说明
1：大曲率混杂结构零件(零件)，2：成型工装，3：可调工装，4：保持支座。
具体实施方式
以下结合说明书附图，对本申请的实施方式进行描述，以下的描述为示例性的，并非对本申请的限制。
本实施方式的大曲率混杂结构零件的外型控制方法适用于使用阴模成型方式对金属与复合材料胶接的大曲率混杂结构零件(以下简称为零件)进行成型的情况。借助可调工装，对大曲率混杂结构零件的成型工装的工装型面进行调整，从而实现对零件外型的精确控制。
参照图1说明本实施方式的大曲率混杂结构零件的外型控制方法的流程。
步骤S1、在本实施方式的大曲率混杂结构零件的外型控制方法中，对待制造的零件的外型特点进行分析。
步骤S2、进行仿真分析，根据仿真分析结果及零件特点，确定零件的外型中可能的超差区域及超差范围，并确定成型工装的设计参数。在此，以具有零件成型所需的刚性、且具备一定程度的可调性的方式选择成型工装的厚度。进行仿真分析可以是对待制造的零件的外型进行仿真分析。
步骤S3、根据成型工装的设计参数制造成型工装，在成型工装的工装型面的与零件的外型中可能的超差区域相应的位置设置可调点。
步骤S4、根据零件的外型特点和易变形区域，设计并制造可调工装。在此，可调范围应满足三维可调要求，根据可调范围选择可调工装的材质等。并且，为了保证零件的外型要求，可调工装应满足可操作性强，适合激光跟踪仪等检测设备使用。
步骤S5、根据零件的外型，利用可调工装将成型工装的工装型面调整成待制造的零件所需的理论型面，使用调整后的成型工装对零件进行成型。
步骤S6、对利用调整后的成型工装以理论型面成型得到的零件的外型进行检测分析，得到超差区域及超差范围。
步骤S7、利用可调工装对工装型面的与所得到的超差区域相应的可调点进行调整，使用调整后的成型工装再次对零件进行成型。
步骤S8、对所得到的零件外型进行检测，分析超差区域及超差范围，判断是否满足外型要求。在满足外型要求的情况下(步骤S8：是)，结束对成型工装的调整，得到理想的成型工装的工装型面(步骤S9)。在不满足外型要求的情况下(步骤S8：否)，返回到步骤S7，对工装型面进行调整，使用调整后的成型工装再次对零件进行成型，直至得到完全满足零件的外型要求的成型工装的工装型面。
在零件成型步骤中，还包括第一检测判断步骤，即，使用激光跟踪仪对调整后的成型工装的工装型面进行检测，判断所述成型工装的工装型面是否被调整成理论型面。
在零件外型的控制步骤中，还包括第二检测判断步骤，即，使用激光跟踪仪对调整后的成型工装的工装型面进行检测，判断所述成型工装的工装型面是否被调整成新要求的工装型面。
在此，在步骤S5及步骤S7中，可以使用激光跟踪仪等检测设备对成型工装的工装型面进行检测，判断成型工装的工装型面是否被调整成理论型面或新要求的工装型面。
根据本实施方式的大曲率混杂结构零件的外型控制方法，能够实现对大曲率混杂结构零件外型的精确控制，并且，可控性强、通用性强、操作简单、成本低、效率高。
【实施例】
以下，参照实施例，列举示例性零件对本申请的大曲率混杂结构零件的外型控制方法进行说明。图2是表示实施例的待制造的零件的立体图，图3是表示实施例的成型工装的可调区域的示意图，图4是表示实施例的可调工装的结构的示意图。
图2所示的零件1是金属与复合材料胶接的大曲率混杂结构零件，能够使用阴模成型来制造。以下，说明在制造过程中对该零件的外型进行控制的方法。
对待制造的零件1的外型特点进行分析。
进行仿真分析，根据仿真分析结果及零件特点，确定该零件1的外型中可能的超差区域及超差范围，并确定成型工装2的设计参数。在此，以具有零件成型所需的刚性、且具备一定程度的可调性的方式选择成型工装2的厚度。
根据设计参数制造成型工装2，并且，如图3所示，在该成型工装2的工装型面的与零件1的外型中可能的超差区域相应的位置设置可调区域及可调点。可调点的数量根据零件1可能变形的程度而设置。
根据零件1的外型特点和易变形区域，设计并制造可调工装3。在此，如图4所示，使用在支撑框架上设有螺纹孔、并使调节螺栓贯穿于螺纹孔的多个调节机构。并且，将调节螺栓的一端连接于多个可调点的位置。能够通过对调节螺栓进行旋转操作来调整(内推或外拉)成型工装2的工装型面。在此，如图4所示，设置保持支座4对可调工装3进行保持、支承。
根据零件1的外型，利用制造好的可调工装3将成型工装2的工装型面调整成待制造的零件1所需的理论型面，使用激光跟踪仪等检测设备对成型工装2的工装型面进行检查。使用调整后的成型工装2对零件1进行成型，对金属与复合材料胶接的混杂结构零件进行手工铺贴，在入罐前检查真空泄露情况，达到要求后放入热压罐进行固化。
在零件1固化后，进行脱模及机械加工，使用检测设备对利用成型工装2以理论型面成型得到的零件1的外型进行检测，根据检测结果，找出超差区域及超差范围，并在成型工装2上进行明确，同时根据超差情况确定工装型面的调整范围。
根据新的型面要求，利用可调工装3对成型工装2的工装型面进行调整，使用激光跟踪仪等检测设备对成型工装2的工装型面进行检查。
使用调整后的成型工装2再次对零件进行成型(成型方法同上)。对所得到的零件进行外型检测，分析超差区域及超差范围，判断是否满足外型要求。在满足外型要求的情况下，结束对成型工装2的调整，得到理想的成型工装的工装型面。在不满足外型要求的情况下，对成型工装2的工装型面进行调整，使用调整后的成型工装2对零件进行成型，反复迭代直至得到完全满足零件的外型要求的成型工装的工装型面。
由此，得到具有完全满足零件的外型要求的工装型面的成型工装，并能够将该成型工装重复性地投入零件制造。
根据本申请的大曲率混杂结构零件的外型控制方法，能够得到以下效果。
(1)可控性强：借助成型工装的可调点，仅对超差区域进行调整，避免了人工修模对超差边缘区域的影响，也使整个零件外型完全可控；
(2)通用性强：该方法可应用于多类大曲率混杂结构零件的阴模成型，每套工装可反复使用，无需重复定制工装；
(3)操作简单：操作人员仅需借助激光跟踪仪对工装型面的可调点进行调整，无需其他额外操作(如辅助定位装置等)；
(4)成本低：虽然需要几次试模，但是相比于反复修理工装型面或者重制工装的情况，本申请不仅能够降低成本，而且能够缩短零件制造周期，也能够重复利用；
(5)效率高：由于操作便捷，达到理想型面后即可限制工装调整，在一个状态下可长期使用，能够有效提高生产效率。
图5是本申请提供的一种大曲率混杂结构零件的外型控制装置的结构示 意图。本申请实施例所提供的大曲率混杂结构零件的外型控制装置可执行本申请任意实施例所提供的大曲率混杂结构零件的外型控制方法，该装置包括以下模块。
零件外型分析模块51，设置为对待制造的所述大曲率混杂结构零件的外型进行分析；
成型工装设计参数的选择模块52，设置为进行仿真分析，根据仿真分析结果及零件特点，确定所述大曲率混杂结构零件的外型中的超差区域及超差范围，并确定成型工装的设计参数；
成型工装的制造模块53，设置为根据所述成型工装的设计参数制造所述成型工装，在所述成型工装的工装型面的与所述大曲率混杂结构零件的外型中的超差区域相应的位置设置可调点；
可调工装的设计及制造模块54，设置为根据所述大曲率混杂结构零件的外型特点和易变形区域，设计并制造可调工装；
零件成型模块55，设置为根据所述大曲率混杂结构零件的外型，利用所述可调工装将所述成型工装的工装型面调整成待制造的所述大曲率混杂结构零件的理论型面，使用调整后的成型工装对所述大曲率混杂结构零件进行成型；和
零件外型的控制模块56，设置为对利用所述调整后的成型工装以所述理论型面成型得到的所述大曲率混杂结构零件的外型进行检测分析，得到检测分析后的超差区域及超差范围，利用所述可调工装对调整后的工装型面的与所得到的检测分析后的超差区域相应的可调点进行调整，使用调整后的成型工装对所述大曲率混杂结构零件进行成型，对制造出的所述大曲率混杂结构零件的外型进行检测分析并对所述成型工装的工装型面进行调整，反复迭代直至得到完全满足所述大曲率混杂结构零件的外型要求的成型工装的工装型面。
在上述实施例的基础上，在所述成型工装设计参数的选择模块中，以具有零件成型所需的刚性、且具备可调性的方式选择所述成型工装的厚度。
在上述实施例的基础上，在所述零件成型模块中，还包括第一检测判断模块，设置为：使用激光跟踪仪对所述调整后的成型工装的工装型面进行检测，判断所述调整后的成型工装的工装型面是否被调整成所述理论型面。
在上述实施例的基础上，在所述零件外型的控制模块中，还包括第二检测判断模块，设置为：使用激光跟踪仪对调整后的成型工装的工装型面进行检测，判断所述成型工装的工装型面是否被调整成新要求的工装型面。
本申请实施例所提供的大曲率混杂结构零件的外型控制装置可执行本申请任意实施例所提供的大曲率混杂结构零件的外型控制方法，具备执行方法相应的功能模块和效果。
图6为本申请提供的一种设备的结构示意图，如图6所示，该设备包括处理器60、存储器61、输入装置62和输出装置63；设备中处理器60的数量可以是一个或多个，图6中以一个处理器60为例；设备中的处理器60、存储器61、输入装置62和输出装置63可以通过总线或其他方式连接，图6中以通过总线连接为例。
存储器61作为一种计算机可读存储介质，可用于存储软件程序、计算机可执行程序以及模块，如本申请实施例中的大曲率混杂结构零件的外型控制方法对应的程序指令/模块。处理器60通过运行存储在存储器61中的软件程序、指令以及模块，从而执行设备的多种功能应用以及数据处理，即实现上述的方法。
存储器61可包括存储程序区和存储数据区，其中，存储程序区可存储操作系统、至少一个功能所需的应用程序；存储数据区可存储根据终端的使用所创建的数据等。此外，存储器61可以包括高速随机存取存储器，还可以包括非易失性存储器，例如至少一个磁盘存储器件、闪存器件、或其他非易失性固态存储器件。在一些实例中，存储器61可包括相对于处理器60远程设置的存储器，这些远程存储器可以通过网络连接至设备。上述网络的实例包括但不限于互联网、企业内部网、局域网、移动通信网及其组合。
输入装置62可设置为接收输入的信息等，以及产生与设备的用户设置以及功能控制有关的信号输入。输出装置63可包括显示屏等显示设备。
本申请实施例还提供一种包含计算机可执行指令的存储介质，所述计算机可执行指令在由计算机处理器执行时用于执行一种大曲率混杂结构零件的外型控制方法，在采用阴模成型方式对大曲率混杂结构零件进行成型的情况下使用，其中，所述方法包括：
零件外型分析步骤，包括：对待制造的所述大曲率混杂结构零件的外型进行分析；
成型工装设计参数的选择步骤，包括：进行仿真分析，根据仿真分析结果及零件特点，确定所述大曲率混杂结构零件的外型中的超差区域及超差范围，并确定成型工装的设计参数；
成型工装的制造步骤，包括：根据所述成型工装的设计参数制造所述成型工装，在所述成型工装的工装型面的与所述大曲率混杂结构零件的外型中 的超差区域相应的位置设置可调点；
可调工装的设计及制造步骤，包括：根据所述大曲率混杂结构零件的外型特点和易变形区域，设计并制造可调工装；
零件成型步骤，包括：根据所述大曲率混杂结构零件的外型，利用所述可调工装将所述成型工装的工装型面调整成待制造的所述大曲率混杂结构零件的理论型面，使用调整后的成型工装对所述大曲率混杂结构零件进行成型；和
零件外型的控制步骤，包括：对利用所述调整后的成型工装以所述理论型面成型得到的所述大曲率混杂结构零件的外型进行检测分析，得到检测分析后的超差区域及超差范围，利用所述可调工装对调整后的工装型面的与所得到的检测分析后的超差区域相应的可调点进行调整，使用调整后的成型工装对所述大曲率混杂结构零件进行成型，对制造出的所述大曲率混杂结构零件的外型进行检测分析并对所述成型工装的工装型面进行调整，反复迭代直至得到完全满足所述大曲率混杂结构零件的外型要求的成型工装的工装型面。
本申请实施例所提供的一种包含计算机可执行指令的存储介质，计算机可执行指令不限于如上所述的方法操作，还可以执行本申请任意实施例所提供的大曲率混杂结构零件的外型控制方法中的相关操作。存储介质可以是非暂态(non-transitory)存储介质。
通过以上关于实施方式的描述，本申请可借助软件及必需的通用硬件来实现，也可以通过硬件实现。本申请可以以软件产品的形式体现出来，该计算机软件产品可以存储在计算机可读存储介质中，如计算机的软盘、只读存储器(Read-Only Memory，ROM)、随机存取存储器(Random Access Memory，RAM)、闪存(FLASH)、硬盘或光盘等，包括多个指令用以使得一台计算机设备(可以是个人计算机，服务器，或者网络设备等)执行本申请多个实施例所述的方法。
上述装置的实施例中，所包括的多个单元和模块只是按照功能逻辑进行划分的，但并不局限于上述的划分，只要能够实现相应的功能即可；另外，多个功能单元的名称也只是为了便于相互区分，并不用于限制本申请的保护范围。

Claims (4)

  1. 一种大曲率混杂结构零件的外型控制方法，在采用阴模成型方式对大曲率混杂结构零件进行成型的情况下使用，其中，所述方法包括：
    零件外型分析步骤，包括：对待制造的所述大曲率混杂结构零件的外型进行分析；
    成型工装设计参数的选择步骤，包括：进行仿真分析，根据仿真分析结果及零件特点，确定所述大曲率混杂结构零件的外型中的超差区域及超差范围，并确定成型工装的设计参数；
    成型工装的制造步骤，包括：根据所述成型工装的设计参数制造所述成型工装，在所述成型工装的工装型面的与所述大曲率混杂结构零件的外型中的超差区域相应的位置设置可调点；
    可调工装的设计及制造步骤，包括：根据所述大曲率混杂结构零件的外型特点和易变形区域，设计并制造可调工装；
    零件成型步骤，包括：根据所述大曲率混杂结构零件的外型，利用所述可调工装将所述成型工装的工装型面调整成待制造的所述大曲率混杂结构零件的理论型面，使用调整后的成型工装对所述大曲率混杂结构零件进行成型；和
    零件外型的控制步骤，包括：对利用所述调整后的成型工装以所述理论型面成型得到的所述大曲率混杂结构零件的外型进行检测分析，得到检测分析后的超差区域及超差范围，利用所述可调工装对调整后的工装型面的与所得到的检测分析后的超差区域相应的可调点进行调整，使用调整后的成型工装对所述大曲率混杂结构零件进行成型，对制造出的所述大曲率混杂结构零件的外型进行检测分析并对所述成型工装的工装型面进行调整，反复迭代直至得到完全满足所述大曲率混杂结构零件的外型要求的成型工装的工装型面。
  2. 根据权利要求1所述的方法，其中，
    在所述成型工装设计参数的选择步骤中，以具有零件成型所需的刚性、且具备可调性的方式选择所述成型工装的厚度。
  3. 根据权利要求1或2所述的方法，其中，
    在所述零件成型步骤中，还包括第一检测判断步骤，包括：使用激光跟踪仪对所述调整后的成型工装的工装型面进行检测，判断所述调整后的成型工装的工装型面是否被调整成所述理论型面。
  4. 根据权利要求3所述的方法，其中，
    在所述零件外型的控制步骤中，还包括第二检测判断步骤，包括：使用激光跟踪仪对调整后的成型工装的工装型面进行检测，判断所述成型工装的工装型面是否被调整成新要求的工装型面。
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