航空长梁整体结构件加工变形预测及校正分析

Analysis of beam aerospace monolithic components machining deformation prediction and correction

航空整体结构件的加工变形和变形校正是制约结构件加工效率的瓶颈技术,针对长梁零件加工后出现变形问题,构建薄壁长梁整体结构件加工变形有限元模型进行数值计算.研究表明,在毛坯初始应力和加工应力的作用下,长梁件出现弯曲扭转复合变形,工件结构刚度不对称是导致工件弯曲变形的重要原因.以变形结果作为校正目标模型,进行加载-卸载反弯和扭转校正分析,对校正参数、校正载荷施加形式及校正效果等关键技术进行研究.根据长梁整体结构件变形校正图谱,当在-Y方向施加9 050N4点反弯校正载荷,在垂直X顺时针方向施加145×10~3 N·m矫正扭矩时,可以得到理想的校正效果.

The machining deformation of aerospace monolithic components is bottleneck problem for aviation manufacturing industry. We construct the beam machining deformation and distortion correction finite element model to study the problem. According to the finite element method （FEM） result, deformation characteristics were obtained. Studies show that the bending and torsion deformation is a universal phenomenon for the beam aerospace monolithic components under the coupling effect of blank original residual stresses and machining residual stress, and the asymmetry structure stiffness of the beam is an important reason leading to deformation. Deformation characteristics were used to evaluate the correcting effect. Correcting key technology such as determination of straightening parameters,anti-bend and anti-twist load were studied. For typical deformational beam, correcting characteristics and correcting rule were given. The ideal correction results were 9 050 N anti-bend load in - Y direction and 145 ×10^3 N·m anti-twist load were applying to the example.