伺服控制下非等厚板料体积成形机理及流动控制研究

项目名称： 伺服控制下非等厚板料体积成形机理及流动控制研究

项目编号： No.51475296

项目类型： 面上项目

立项/批准年度： 2015

项目学科： 机械、仪表工业

项目作者： 赵震

作者单位： 上海交通大学

项目金额： 82万元

中文摘要： 在高性能化制造已成为我国制造业重要发展战略的今天，具有结构和性能优势的板料体积成形技术已越来越多用于含三维立体特征零件的近净成形。然而，以等厚度板料为坯料的板料体积成形已无法满足一些复杂立体特征零件的成形能力需求，这对成形装备和技术提出了新的挑战。本项目旨在通过采用非等厚板为坯料进行板料体积成形的研究，实现复杂立体特征零件的制造。一方面，建立表征非等厚板的厚度域函数，将多种约束引入非等厚板的厚度域拓扑优化，从而获得面向制造的非等厚板最优拓扑布局，实现有益的局部聚料；另一方面，引入伺服控制技术中的变速、保压、回弹模式，分析非等厚板在复杂应力条件下不同运动模式造成材料宏观力学性能变化的内在机理。在此基础上，通过相关物理实验与数值模拟，对成形缺陷和金属流动加以控制和改善，最终建立一整套伺服控制下以非等厚板为坯料的板料体积成形工艺方法。

中文关键词： 板料体积成形；伺服控制；非等厚板；流动控制；拓扑优化

英文摘要： Under the current situation that high-performance manufacturing has become the significant developing strategy of manufacturing industry in China, sheet bulk forming technology with advantage of structure and high performance has been increasingly used to manufacture the 3D functional part in net shape. However, sheet bulk forming technology using the sheet of equal thickness cannot meet the forming capacity needs of some complex parts with three-dimensional characteristics, which brings new requirement and challenge to the press and equipment. For this purpose, servo-control technology as well as sheet of unequal thickness is brought into sheet bulk forming process in this project to realize the production of some complex parts with three-dimensional characteristics.On one hand, through establishing thickness domain function to characterize sheet of unequal thickness and introducing a variety of constaint into the thickness domain for Topology Optimization, in order to obtain optimal topological layout for manufacturing, through which the beneficial local metal accumulation is realized. On the other hand, the speed changing, pressure conservation and rebounding modes are brought into the servo-control forming, and the inherent mechanism of the macroscopic mechanical properties of the sheet of unequal thickness under complex stress conditions caused by the internal mechanism of the different movement patterns is analyzed. Through the relevant physical experiments and numerical simulation, the flow of metal forming defects will be well controlled and improved, and finally, a series of process methodology related to sheet bulk forming process under servo control condition will be established.

英文关键词： sheet bulk forming;servo-control;tailored blank of unequal thickness;flow control;topology optimization