Die-face compensation algorithm in stretch forming of aircraft skin over reconfigurable compliant tooling
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摘要: 针对单曲形蒙皮零件,建立了有限元数值模拟的离散模型和等效模型,通过对成形计算时间、垫层变形量和成形零件外形的比较,验证了等效模型的高效性和可靠性.为了消除垫层变形和板料回弹对成形精度的影响,采用有限元等效模型技术,基于位移调整法,提出了先进行板料回弹补偿再进行垫层变形补偿的模面补偿算法,并应用该算法分别对单曲形和双曲形蒙皮零件进行了拉形模面补偿分析.在得到的补偿模面上进行了单曲形和双曲形蒙皮零件成形试验,采用非接触光学测量系统进行数字化测量后,发现成形零件外形误差均在允许范围(±0.5 mm)之内,满足精度要求,验证了该模面补偿算法的有效性.Abstract: Two finite element models of a single curvature part, discrete and equivalent models of stretch forming over reconfigurable compliant tooling, were set up. The calculation times, rubber deformations and part shapes in two models were compared. The result shows the equivalent model is reliable and more efficient. To eliminate the influence of springback and the interpolator deformation on the part shape fidelity, a die-face compensation algorithm was proposed based on displacement adjustment method and equivalent model. In the algorithm springback compensation and deformation compensation of interpolator were performed in sequence. This algorithm was applied to compensate the die-faces of a single curvature part and a double curvature part. Finally, the two parts were stretch-formed over compensated die-faces and measured by non-contact three-dimensional measurement techniques. The results show that the shape errors are both within tolerance (±0.5 mm) and meet the requirements. It is proved that the algorithm is effective.
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