电磁脉冲成形技术新进展及其在飞机蒙皮件制造中的应用

New Development of Electromagnetic Pulse Forming Technology and Its Application in Aircraft Skin Parts Manufacturing

电磁脉冲成形是一种利用脉冲磁场力对金属工件进行高速加工的方法。与传统工艺相比,电磁脉冲成形能提高难变形材料的成形极限、降低回弹,从而为铝合金的难加工问题提供了有效的解决途径。以筒形件拉深、大型椭球零件制造、V形零件弯曲回弹控制3个难点问题为例,介绍近年来电磁脉冲成形技术所出现的多向磁场力驱动材料按需流动、磁场力分区加载、高频振荡效应等。在此基础上,提出磁场力分区加载的飞机蒙皮件成形方法。试验和模拟研究发现,纯拉形后蒙皮件主要发生弹性变形,导致最终的回弹大;而电磁脉冲成形后,蒙皮件上的弹性变形转化为塑性变形,最终零件的回弹大幅度降低。

Electromagnetic pulse forming(EMF)is a method of high-speed machining method for metal workpieces by using pulsed magnetic force.Compared with traditional processes,EMF can increase the forming limit of difficult-to-deform materials and reduce springback.Thus,it provides an effective solution to the difficult processing problem of aluminum alloy.Based on the difficult forming problems of cylindrical parts drawing,large ellipsoidal parts manufacturing,V-shaped part bending and springback control,we introduce some new technologies such as multi-directional magnetic force driving materials,magnetic field force partition loading,and high frequency oscillation effect.On this basis,the method of shaping the aircraft skin parts by magnetic field force partition loading is proposed.Experimental and simulation results show that the sheet undergoes mainly elastically deformed and results in a large springback after pure stretching.However,the elastic deformation on the sheet is transformed into plastic deformation,and the springback is greatly reduced after EMF.