第43卷第2期 Vol. 43No. 2
假压技木
FORGING & STAMPING TECHNOLOGY
大曲率高翻边钣金零件橡皮成形起皱控制
白颖，贾敏，李善良，乔锋敏，蔡燕敏，陈磊”
2018年2月 Feb.2018
（1．中航飞机股份有限公司，陕西西安710089；2．杭州电子科技大学机械设计研究所，浙江杭州310018）
摘要：起皱是橡皮液压成形主要缺陷之一，大飞机固定前缘安装着一系列鱼头状钣金隔板件，曲率大、翻边高，成形时易起皱，控制起皱是需要解决的关键间题。借助于PAMSTAMP板料成形模拟软件建立橡皮成形有限元模型，对大曲率、高翻边钣金件橡皮成形起皱缺陷进行数值分析，研究侧压块模具结构与压边阅模具结构对橡皮成形消皱技术的影响效果，确定展开毛坏、模具结构、橡皮硬度等的最佳数值，并加以试验验证，最终形成了一种可直接采用无余量展开毛坏完鉴机械加工凸弯边零件的橡皮成形技术，实现了大曲率、高翻边零件的无皱橡皮精确成形，为大型飞机钣金制造提供参考
关键词：橡皮成形；大率；凸弯边；数值模拟；起皱 DOI: 10. 13330/j. issn. 1000-3940. 2018. 02. 008
中图分类号：TG386.1
文献标识码：A
文章编号：1000-3940（2018）02-0038-06
Wrinklingcontrolofrubberformingforsheetmetalpartswith
large curvature and high flange
Bai Ying', Jia Min', Li Shanliang', Qiao Fengmin', Cai Yanmin', Chen Lei
(1. AVIC Aircraft Co. , Ld. , Xi'an 710089, China; 2. Institute of Mechanical Design, Hangzhou Dianzi
University, Hangxhou 310018, China)
Abstract : Wrinkling is one of the main defects in rubber foming process. There are a range of sheet metal bulkheads like fish head in stalled in the leading edges of large airerafts, which are of large curvature and high flange, especially easy to wrinkle in forming. So wrin kling control is the key problem to be solved, Therefore, a finite element model of nubber forming was built by software PAMSTAMP, and the wrinkling defects of sheet metal parts with large curvature and high flange were analyzed. Furthermore, the influences of die structure with the side pressure block or blankholder on the wrinkling reduction technology in the rubber forming were investigated, and the optimum values of expanded blank, die stnucture and rubber handness were detemined. Through experimental verification, a nubber foming method was developed, which could fully manufacture blank expanded without allowanee to convex bending parts. Thus, precise rubber forming without wrinkle of sheet metal parts with large curvature and high flange was realized, which provided a reference for the manufacturing of large aireraft sheet metal parts.
Key words : rubber forming; large curvature; convex flange; numerical simulation; wrinkling
近些年，国内航空领域钣金成形机械化程度越来越高，橡皮囊液压成形工艺作为一种先进的柔性板料成形技术，凭借操作便捷、工装成本低、表面质量高等诸多优势越来越受青，特别适合多品种、小批量的产品生产[1-2]。
钣金零件“凸”弯边特征又称压缩弯边3}，是飞机制造中常见结构，该类零件在成形过程中弯边区毛料会因收缩变形过大而起皱。通常凸形弧度越大、翻边越高，成形中弯边区毛料收缩变形越剧烈、越容易出现褶皱、甚至死皱。在航空企业，通常将
收稿日期：20170815；修订日期：20171119 作者简介：白题（1972-），女，学士，研究员
万方擎端a；oji_de163.com
凸型曲率半径小于200mm、翻边高度大于25mm 的钣弯零件界定为“大曲率、高副边”类零件，现加工方法多以工人手工成形为主，而手工成形钣金零件不得不依赖于榔头的频繁敲击来实现，零件表面锤痕明显、工人劳动强度大、成形精度低、材料出现冷作硬化趋势，内部残余应力、厚度不均、表面坑坑洼洼对飞机安全可靠性造成一定威胁。
目前，控制凸弯边起皱的方法很多，应用比较广泛的是侧压块方法[3)，此方法考虑的因素较多，侧压块的角度、侧压块与模具主体间距、侧压块模具转角半径、零件凸曲线弧度、翻边高度、初始坏料大小、材料厚度、成形压力、橡皮特性等都会影响最终成形结果，每一项零件的研究成果不具备代表性，为此一直没有一个定性结论