航空大型复杂钛框预锻成形初始毛坯优化

Optimization of initial billet for preforging forming of aviation large-sized complex titanium alloy bulkhead

以某TA15钛合金框为例,采用数值模拟、响应面分析及物理模拟实验相结合的方法对预锻成形的初始毛坯形状尺寸进行了优化。构建了初始毛坯的参数化几何模型;建立了预锻成形有限元模型和响应面实验方案;以型腔各区域同时靠模为目标,根据不同初始毛坯的模拟结果,建立毛坯几何尺寸与模具型腔充填之间的定量关联关系,并通过极值求解计算出最优毛坯几何尺寸;最后采用有限元模拟和物理模拟实验验证了初始毛坯优化的可靠性和准确性。结果表明,该方法能有效克服大型复杂钛框预锻成形中常见的填充不满、成形载荷过大等问题,实现预锻件在型腔不同区域同时靠模。

Taking a TA15 titanium alloy bulkhead as an example,the combined method of numerical simulation,response surface analysis and physical simulation tests were used to optimize the shape and size of the initial billet formed by preforging forming.The parametric geometry model of the initial billet was constructed,and the finite element model of preforging forming and response surface test schemes were established.Aiming at simultaneous modeling of each area of the cavity,based on the simulation results of different initial billets,the quantitative correlation between geometric size of billet and die cavity filling was established,and the optimal geometric size of billet was calculated by solving the extreme value.Finally,the finite element simulation and physical simulation tests were used to verify the reliability and accuracy of the initial billet optimization.The results show that the method can effectively overcome the common problems such as insufficient filling and excessive forming load in the preforging forming of large-sized complex titanium alloy bulkhead,and realize the simultaneous modeling of the preforging parts in different areas of the cavity.