Optimization of Fixture Number in Large Thin-Walled Parts Assembly Based on IPSO

There are lots of researches on fixture layout optimization for large thin-walled parts.Current researches focus on the positioning problem,i.e.,optimizing the positions of a constant number of fixtures.However,how to determine the number of fixtures is ignored.In most cases,the number of fixtures located on large thin-walled parts is determined based on engineering experience,which leads to huge fixture number and extra waste.Therefore,this paper constructs an optimization model to minimize the number of fixtures.The constraints are set in the optimization model to ensure that the part deformation is within the surface profile tolerance.In addition,the assembly gap between two parts is also controlled.To conduct the optimization,this paper develops an improved particle swarm optimization(IPSO)algorithm by integrating the shrinkage factor and adaptive inertia weight.In the algorithm,particles are encoded according to the fixture position.Each dimension of the particle is assigned to a sub-region by constraining the optional position range of each fixture to improve the optimization efficiency.Finally,a case study on ship curved panel assembly is provided to prove that our method can optimize the number of fixtures while meeting the assembly quality requirements.This research proposes a method to optimize the number of fixtures,which can reduce the number of fixtures and achieve deformation control at the same time.

Forming limits under multi-index constraints in NC bending of aluminum alloy thin-walled tubes with large diameters

With increasing diameters of aluminum alloy thin-walled tubes (AATTs), the tube forming limits, i.e. the minimum bending factors, and their predictions under multi-index constraints including wrinkling, thinning and flattening have been being a key problem to be urgently solved for improving tube forming potential in numerical control (NC) bending processes of AATTs with large diameters. Thus in this paper, a search algorithm of the forming limits is put forward based on a 3D elastic-plastic finite element (FE) model and a wrinkling energy prediction model for the bending processes under axial compression loading (ACL) or not. This algorithm enables to be considered the effects of process parameter combinations including die, friction parameters on the multi-indices. Based on this algorithm, the forming limits of the different size tubes are obtained, and the roles of the process parameter combinations in enabling the limit bending processes are also revealed. The followings are found: the first, within the appropriate ranges of friction and clearances between the different dies and the tubes enabling the bending processes with smaller bending factors, the ACL enables the tube limit bending processes after a decrease of the mandrel ball thickness and diameters; then, without considering the effects of the tube geometry sizes on the tube constitutive equations, the forming limits will be decided by the limit thinning values for the tubes with diameters smaller than 80 mm, while the wrinkling for the tubes with diameters no less than 80 mm. The forming limits obtained from this algorithm are smaller than the analytical results, and reduced by 57.39%; the last, the roles of the process parameter combinations in enabling the limit bending processes are verified by experimental results.

Mechanics analysis of thin-walled box continuous girder with variable cross-sections in considering effect of large deflection and shear lag

In order to study the mechanics behavior of a thin-walled box continuous girder with variable crosssections,using potential variation theories,considering the effect of shear lag of flange’s stress and the nonlinear geometry of vertical displacement,and evolving five generalized displacements with the spline function,the large deflection problem of the thin-walled box continuous girder with variable cross-section was transformed to a nonlinear algebraic equation,which was solved using the Newton-Raphon iterative method.The results of the calculation show that different shear lag warp functions to the cantilever,top and bottom plate should be taken to analyze the mechanics behavior of the thin-walled box continuous girder reliably.The thin-walled box continuous girder with variable cross-sections has more reasonable stress state and is more adaptable for the longitudinal change of internal forces than that with equal crosssections.The effect of large deflection on the stress and displacement of the thin-walled box continuous girder with variable cross-sections depends on the values of the load.

有色金属大型壁板型材连续轧挤初探

利用自行设计改装的连续轧挤设备模拟大型壁板型材的成形.以橡皮泥作为模拟试验材料,在由二辊轧机改装得到的连续轧挤设备上进行试验,模拟了宽×厚为98 mm×1 mm的板材连续轧挤生产过程.橡皮泥模拟试验及连续轧挤的工程法力学分析证明,利用连续轧挤法制备大型壁板型材是可行的,对大型壁板型材的制备有一定的指导作用.

Residual Stress Relaxation of Thin‑walled Long Stringer Made of Aluminum Alloy 7050‑T7451 under Transportation Vibration

Thin-walled long stringer made of aluminum alloy 7050-T7451 is prone to deformation during transportation,so a research of residual stress relaxation was launched in this paper.The transport resonance stress of long stringer was analyzed based on the power spectral density of road transport acceleration.The residual stress relaxation experiment of aluminum alloy 7050-T7451 under different equivalent stress levels was designed and carried out.According to the amount of residual stress relaxation in the experiment,an analytical model was established with the equivalent stress level coefficient.The deflection range of long stringer was evaluated under different damping ratios.The results show that when the equivalent stress exceeds 0.8σ0.2,the residual stress relaxation of the thin-walled samples occurs.The residual stress relaxation increases linearly with the equivalent stress,which is logarithmically related to the loading cycle.The deformation caused by residual stress relaxation of the long stringer is proportional to the square of the length and the bending moment caused by stress rebalance,and inversely proportional to the moment of inertia of the structure.As the damping ratio decreases from 0.03 to 0.01,the total deflection of the long stringer increases from 0 to above 1.55 mm.

大型超薄不锈钢双曲面机身下壁焊接制造技术

针对大型超薄不锈钢双曲面机身下壁焊接组合件制造难度大的特点,研究制定了工艺制造方案,设计了合理的制造工艺参数和焊接型架,实现了机身下壁焊接组合件的制造技术,为今后类似焊接组合件制造奠定了良好的技术基础。