基于响应面法橡皮成形侧压块参数优化及验证

橡皮成形是飞机钣金零件制造的一种重要的成形工艺,为提高典型零件橡皮成形的效率,针对橡皮成形过程中产生的起皱问题,基于响应面法对侧压块参数进行优化.首先对新淬火状态下的铝合金板料进行材料试验,分析了其成形性能指标参数,为有限元模拟提供材料本构关系与模型;然后以起皱量化为优化目标,将凸弯边的最大增厚率作为侧压块优化的目标函数,为得到典型零件橡皮成形侧压块精确的几何参数,采用Abaqus有限元软件对带侧压块成形过程进行正交模拟试验,得出侧压块几何参数对起皱指标影响程度的主次关系,并得到最优的参数水平组合.基于响应面建模方法建立了侧压块最优几何参数和起皱指标之间的多项式关系,并用遗传算法进行参数优化,利用优化后的工艺参数进行有限元模拟,阐述了侧压块防皱原理;最后通过实际成形试验,验证了有限元模拟的可行性和优化方法的可靠性.

Parameters optimization and validation of rubber forming of side blank holder based on response surface methodology

Rubber forming is one of the most important sheet metal forming technologies in aircraft manufacturing. In order to improve the efficiency of the rubber forming of typical parts, the wrinkling in the process of rubber forming was studied, and the parameters of the side of the blank holder were optimized based on the response surface method. Formability parameters at the conditions of different aging times in as-quenched state of aluminum alloys were analyzed via tensile strength tests, providing an accurate material constitutive model for finite element modeling of rubber forming. Wrinkling was quantified as objective functions. In order to obtain the geometric parameters of side blank holder for the rubber forming of typical part, the finite element software, Abaqus, was used to simulate the forming process. The primary and secondary relations about the influence of the geometric parameters of the lateral pressure block on the wrinkling index were determined. A polynomial relation between the optimal geometric parameters and forming index was established based on response surface methodology. Parameters optimization was performed using the genetic algorithm. Finite element simulation using the optimal process parameters was carried out to elaborate the anti-wrinkle principle of the side blank holder. The actual forming experiments were performed to clarify the validity of finite element simulation and the reliability of the optimization method of.