5B02铝合金管材数控弯曲成形试验与数值模拟研究

Experiment and numerical simulation research on numerical-controlled bending for 5B02 aluminum alloy tubes

弯管在飞机的液压、燃油、环控、供氧等系统有着广泛的应用。在弯管成形的过程中容易出现起皱、破裂、回弹等缺陷。针对以上问题,将直径为Φ30,Φ50和Φ70 mm的5B02铝合金管材在数控绕弯设备上进行绕弯成形。成形后利用超声波测厚仪测量了管材内外脊线壁厚厚度分布。基于PAM-STAMP建立绕弯过程有限元模型,对厚度分布进行了预测。通过试验测量结果与仿真结果的对比,发现有限元模型能够准确预测厚度分布。其中内侧脊线厚度分布最大相对误差为9.34%,外侧脊线厚度最大相对误差达到4.88%。此结果达到可接受的误差范围,可以用来指导实际生产。

Tubes have been widely applied in hydraulic, fuel, environmental control and oxygen supply system. Wrinkle, rupture and springbaek can frequently appear in the process of bending. Focusing on these problems, the 5B02 aluminum alloy tubes with diameters of Φ30, Φ50, Φ70 mm were bended on the numerical-controlled bending machine. Then, inner and outer crest thicknesses of the formed tubes were measured by the ultrasonic thickness gage. A numerical model of this bending process was established by PAM-STAMP soft- ware, the prediction on the thickness distribution of the formed tubes was carried out. By comparing the experiment results with the simu- lation results, the thickness distribution can be accurately predicted by the finite element model. The maximum relative error of the inner crest thickness distribution is no more than 9. 34% , and the maximum relative error of the outer crest thickness distribution is no more than 4. 88%. The results are within the acceptable error range and can be guidance in tube manufacture.