多向作用力状态下的前缘蒙皮零件成形方法的研究

蒙皮成形技术是航空航天制造领域的一项重要的加工技术,其先进程度是衡量一个国家飞机制造能力和水平的重要标识之一,因此研究蒙皮成形技术对于我国航空制造具有十分重要的意义。通过改变零件成形作用力,改善成形应力状态,充分发挥零件材料塑性;利用拉形成形和压形成形相结合的成形方法,对前缘蒙皮生产过程中存在的回弹问题进行生产性试验和测量分析,实现前缘蒙皮零件精准成形。

Formability determination of AZ31B tube for IHPF process at elevated temperature

Ring hoop tension test and tube bulging test were carried out at elevated temperatures up to 480 ℃to evaluate the formability of AZ31B extruded tube for internal high pressure forming （IHPF） process. The total elongation along hoop direction and the maximum expansion ratio （MER） of the tube were obtained. The fracture surface after bursting was also analyzed. The results show that the total elongation along hoop direction and the MER value have a similar changing tendency as the testing temperature increases, which is quite different from the total elongation along axial direction. Both the total elongation along hoop direction and the MER value increase to a peak value at about 160 ℃. After that, they begin to decrease quickly until a certain rebounding temperature is reached. From the rebounding temperature, they begin to increase rapidly again. Burnt structure appears on the fracture surface when tested at temperatures higher than 420 ℃. Therefore, the forming temperature of the tested tube should be lower than 420 ℃, even though bigger formability can be achieved at higher temperature.

Size effects on plastic deformation behavior in micro radial compression of pure copper

Micro radial compression tests were carried out on cylindrical specimens of pure copper polycrystals with different grain sizes. Experimental results indicated that phenomena of decreasing forming force, increasing scatter of forming force and more irregular surface topography occurred with the increase of grain size. A modified surface model based on dislocations pile-up in surface layer grains, and a flow stress scattering formulation based on standard deviation and grain size distribution were proposed to analyze size effects on forming force in micro compression. The inhomogeneous deformation of surface layer grains was discussed by the main deformation manner of rotation. A good agreement with the experimental results was achieved.

Research on technological parameters of pressure forming with hot granule medium on AA7075 sheet

Hot granule medium pressure forming （HGMF） process is a new process in which granule medium replaces the medium in existing flexible-die hot forming process, such as liquids, gases or viscous medium. Hot forming of light alloy sheet parts can be realized based on the properties of granule medium, such as withstanding high temperature and pressure, filling well, sealing and loading easily. In this work, the forming of AA7075 cylindrical parts by HGMF process is taken as an example to establish the constitutive relation and forming limit diagram （FLD） of AA7075 sheet which is related to temperature by hot uniaxial tensile test of sheet metal. Based on the assumption that granule medium is applied to extended Drucker-Prager linear material model, the finite element model of HGMF process is established and the effect of technological parameters, such as forming temperature, blank-holder gap and drawing ratio, on the sheet metal formability, is studied. The limit drawing ratio curve of AA7075 cylindrical parts at forming temperature of 175-300 ℃ is obtained by HGMF process test, and the limit drawing ratio reaches the maximum value of 1.71 at 250 ℃. The results of numerical simulation are consistent with the results of process test, and the forming force, distribution of wall thichness and form of instability are predicted correctly, which provides reference for the application of HGMF process.

Instability analysis of free deformation zone of cylindrical parts based on hot-granule medium-pressure forming technology

The cylindrical part of sheet metal based on hot-granule medium-pressure forming (HGMF) technology was investigated.The stress functions of the free deformation zone and the fracture instability theory were combined to establish the analytical expression of the critical pressure of punch. The results show that the active friction between the granule medium and the sheet metal, as well as the non-uniform internal pressure presented by the solid granule medium, can obviously improve the forming performance of the sheet metal. The critical pressure of punch increases with the increment of the friction coefficient between the granule medium and sheet metal, as well as the plastic strain ratio, whereas it decreases with the increase of the material-hardening exponent. Furthermore, the impact on the critical pressure from high to low order is the plastic strain ratio, the friction coefficient,and material-hardening exponent. The deep-drawing experiment with HGMF technology on AZ31B magnesium alloy sheet verified the instability theory.Key words: hot-granule

Characteristics of thickness distribution of tailor-welded tube hydroforming

Both experimental and mechanical analyses were carded out to investigate the characteristics of thickness distribution for tailor-welded tube （TWT） hydroforming with dissimilar thickness. Then, the effects of weld-seam position and thickness difference were also revealed. A multiple-diameter tube was formed to reveal the characteristics and the regularity of thickness distribution during TWT hydroforming. It is indicated that there are obvious fluctuations in thickness distribution though the TWTs have the same expansion ratio. The thinning ratio of thinner tube is bigger than that of thicker tube especially in the zone closed to the weld-seam. The difference in thinning ratio between two tube segments can reach 9%. Consequently, sudden and large fluctuation of thickness appears in the zone nearby the weld-seam. The difference in thinning ratio between thinner and thicker tubes enlarges as the thickness difference increases, but improves as length ratio increases. Different strain states are the main reason to induce nonuniform thickness distribution. The difference in thickness is the main reason to induce different strain states on thinner and thicker tubes.

Deformation mechanism and forming properties of 6061Al alloys during compression in semi-solid state

The 6061 semi-solid aluminium alloy feedstocks prepared by near-liquidus casting were compressed in semi-solid state by means of Gleeble-3500 thermal-mechanical simulator.The relationship between the true stress and the true strain at different temperatures and strain rates was studied with the deformation degree of 70%.The microstructures during the deformation process were characterized.The deformation mechanism and thixo-forming properties of the semi-solid alloys were analyzed.The results show that the homogeneous and non-dendrite microstructures of semi-solid 6061Al alloy manufactured by near-liquidus casting technology could be transformed into semi-solid state with the microstructure suitable for thixo-forming which are composed of near-spherical grains and liquid phase with eutectic composition through reheating process.The deformation temperature and strain rate affect the peak stress significantly rather than steady flow stress.The resistance to deformation in semi-solid state decreases with the increase of the deformation temperature and decrease of the strain rate.At steady thixotropic deformation stage, the thixotropic property is uniform, and the main deformation mechanism is the rotating or sliding between the solid particles and the plastic deformation of the solid particles.

Corner forming of AZ61A magnesium alloy tube within warm hydroforming

The comers with small radii on cross sections are crucial for forming hydroformed components with polygonal sections. In this paper, warm hydroforming experiments of AZ61A magnesium alloy tubes were cartied out to study the forming regularity of round comers by using a demonstration part with square sections. Effects of temperature on radius forming, thinning ratio distribution and microstructure were revealed and a component with relative outer corner radius of 3.0 was obtained by warm hydroforming at 240℃. The minimum thickness of the formed square section was located in the transition position between the corner and the straight wall. The thinning ratio of the round corner increased with the increase of forming temperature. Fotmability of the magnesium tube was improved by raising temperature under the effect of dynamic recrystallization at 240℃.

An Improved Technique of Calculating Deflections of Flexural Reinforced Concrete Elements Made of Conventional and High-Strength Concrete

The paper presents an improved technique of calculating total deflections of flexural reinforced concrete elements that takes discrete crack formation into account. The technique is based on determining the curvature of the cross section of reinforced concrete elements with cracks and fissures in the area between cracks. The curvature of the element is calculated using a non-linear function of the deformation of concrete under compression. Approximating dependency of concrete resistance on compression developed by one of the authors is presented. An algorithm of finding the curvature and formulas for calculating curvature and deflection are provided. The function of the curvature distribution along the length of a flexible element is proposed by the authors. The paper also presents the results of the author＇s experimental research. The characteristics of samples tested are described. The experimental research results of deflections of fiexural reinforced concrete elements made of conventional and high-strength concretes are presented. Comparison of the values calculated using the technique with those obtained from the experimental research as well as those calculated according to existing regulations in Russia, USA and Europe is drawn.

Applications and research in frame longeron of hydroforming

The application feasibility of hydroforming in frame longeron large parts is verified for the first time at home. The result of the research on the structure design and process analysis for frame longeron shows that hydroforming can he fully realized. With stiffness is comparison, collision test simulation and cross section force with traditional drawing- assembly welding techniques, it has been found that hydroforming combining has multiple advantages such as light- weight, high stiffness, reduction in the number of parts, high precision, hence reduction the associated machining and welding and so on. It is especially suitable for forming various lightweight components used for the chassis parts in automotive.

Forming and Springback Prediction of Strips Under Multi-square Punch Concave Forming Process Considering Partial-unloading Effects

To further investigate the forming mechanism and springback characteristics of strips under multi-square punch forming (MSPF) considering partial-unloading effects, a series of concave form ing tests of strips are conducted on the MSPF machine. This paper aims to reveal the physical mecha nism of the elastic-plastic deformation in the MSPF process considering the effect of the forming ap proaches, and derive appropriate mathematical interpretations. The theoretical model is firstly estab lished to analyse the concave forming mechanism and springback characteristics of the strip, and its accuracy is then validated by experimental data. The forming history and load evolutions are depicted to explore the required forming capacity through the proposed analytical method. Besides, the paramet ric studies are carried out to discuss their effects on the springback of the strip. The results suggest that the deformation paths of the strip are influenced by the forming approach, and the springback of the strip in convex forming is larger than that in concave forming.

Principle and theoretical analysis of continuous roll forming for three-dimensional surface parts

Continuous roll forming(CRF) is a novel forming process for three-dimensional surface parts,in which a pair of bendable forming rolls is used as sheet metal forming tool.By controlling the gap between the upper and lower forming rolls,sheet metal is non-uniformly extended in the longitudinal direction while it is bent in the transverse direction during the rolling process.As a result,longitudinal bending is gained and a doubly curved surface is formed.With the rotations of the forming rolls,the sheet metal is deformed consecutively,and a three-dimensional surface part is shaped continuously.In this paper,the mechanism of the three-dimensional surface formation in CRF is set forth.Through theoretical analysis of the CRF process,the governing equations for the bending deformation in rolling process are presented.Based on the simplification on the deformation and material model,the formulation to calculate the longitudinal bending deformation is derived,and the methods to design the compression ratio and the roll gap are given,the effects of compression ratio of rolling and the width of blank sheet on the longitudinal bending curvature are analyzed.The forming experiments on typical surface parts and measured results show that forming results with good precision can be obtained by CRF process.

Evidence from pseudomorphous β-quartz phenocryst for decompression of rock-forming and ore-forming processes in Shapinggou porphyry Mo deposit

The Shapinggou porphyry molybdenum(Mo) deposit, located in Jinzhai County, Anhui Province, China, is the largest in the Qinling-Dabie Mo Metallogenic Belt. The intrusive rocks in the Shapinggou Mo ore district formed in the Yanshanian can be divided into two stages based on zircon U-Pb dating and geochemical features. This study focuses on the late stage intrusions(quartz syenite and granite porphyry), which are closely genetically related to molybdenum mineralization. Petrographic observations identified two quartz polymorphs in the quartz syenite and granite porphyry, which were derived from the same magmatic sources and similar evolutionary processes. The quartzes were identified as a xenomorphic β-quartz within quartz syenite, while the quartz phenocrysts within the granite porphyry were pseudomorphous b-quartz, characterized by a hexagonal bipyramid crystallography. The pseudomorphous b-quartz phenocrysts within the granite porphyry were altered from b-quartz through phase transformation. These crystals retained b-quartz pseudomorph. Combined with titanium-inzircon thermometry, quartz phase diagrams, and granitic Q-Ab-Or-H_2O phase diagrams, it is suggested that the quartz syenite and granite porphyry were formed under similar magmatic origins, including similar depths and magmatic crystallization temperatures. However, the β-quartz within quartz syenite indicated that the crystallization pressure was greater than 0.7 GPa, while the original b-quartz within the granite porphyry was formed under pressures between 0.4 and 0.7 GPa. The groundmass of the granite porphyry which formed after the phenocryst indicated a crystallizing pressure below 0.05 GPa. This indicates that the granite porphyry was formed under repetitive and rapid decompression. The decompression was significant as it caused the exsolution of the ore-forming fluids, and boiling and material precipitation during the magmatic-fluid process. The volumetric difference during the phase transformation from b-quartz to β-quartz caused extensive fracturing on the granite porphyry body and the wall rocks. As the main ore-transmitting and ore-depositing structures, these fractures benefit the hydrothermal alteration and stockwork-disseminated mineralization of the porphyry deposit. It is considered that the pseudomorphous β-quartz phenocrysts of the porphyritic body are metallogenic indicators within the porphyry deposits. The pseudomorphous β-quartzes therefore provide evidence for the formation of the porphyry deposit within a decompression tectonic setting.