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弯管在飞机的液压、燃油、环控、供氧等系统有着广泛的应用。在弯管成形的过程中容易出现起皱、破裂、回弹等缺陷。针对以上问题,将直径为Φ30,Φ50和Φ70 mm的5B02铝合金管材在数控绕弯设备上进行绕弯成形。成形后利用超声波测厚仪测量了管材内外脊线壁厚厚度分布。基于PAM-STAMP建立绕弯过程有限元模型,对厚度分布进行了预测。通过试验测量结果与仿真结果的对比,发现有限元模型能够准确预测厚度分布。其中内侧脊线厚度分布最大相对误差为9.34%,外侧脊线厚度最大相对误差达到4.88%。此结果达到可接受的误差范围,可以用来指导实际生产。
Elbow in the aircraft’s hydraulic, fuel, environmental control, oxygen and other systems have a wide range of applications. Bending in the process of bending prone to wrinkles, rupture, rebound and other defects. In response to the above problems, the 5B02 aluminum alloy pipes of Φ30, Φ50 and Φ70 mm in diameter were bent and formed on the CNC bending equipment. After forming, the thickness distribution of the inner and outer spine wall thickness was measured by ultrasonic thickness gauge. Based on PAM-STAMP, a finite element model of winding process was established and the thickness distribution was predicted. By comparing the experimental results with the simulation results, it is found that the finite element model can accurately predict the thickness distribution. Among them, the maximum relative error of the medial ridgeline thickness distribution is 9.34% and the maximum relative error of the lateral ridgeline thickness is 4.88%. This result reaches an acceptable margin of error and can be used to guide actual production.