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2022 Vol. 65, No. 10
Published: 2022-05-15
FEATURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
1
COVER
2022 Vol. 65 (10): 1-1 [
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110
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C0NTENTS
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CONTENTS
2022 Vol. 65 (10): 6-10 [
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100
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FEATURE
14
Research Progress on Novel Tube Forming Technology Based on Magnetorheological Elastomer
XU Yong，LI Hao，GUO Xunzhong，ZHANG Shihong，XIA Liangliang，HU Shenghan
DOI: 10.16080/j.issn1671-833x.2022.10.014
Based on the desperate demand for the complicated hollow part with large diameter ratio in aerospace, a novel tube forming technology based on magnetorheological elastomer (MRE) is proposed. The paper systematically introduced the preparation of MRE, the theory of compression mechanical property of MRE and experimental testing, the development of forming process and the design of tools, construction of finite element (FE) model and FE simulation, the application of the technology in forming complicated tube. The obtained results show that the novel technology can realize the differential loading of the forming pressure to promote the flow of material and effectively resolve the sealing problem during tube hydroforming by applying external magnetic field. In the future, this novel technology may provide forward looking technical support to the integrated precise forming of complicated hollow part with large diameter ratio.
2022 Vol. 65 (10): 14-22 [
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232
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COVER STORY
24
Research on Six-Axis Free Bending Forming Mechanism and Forming Quality Control of Profle Components
GUO Xunzhong，YANG Qiucheng，CHENG Cheng， LIU Chunmei，XU Yong，BAI Xueshan，LI Guangjun
DOI: 10.16080/j.issn1671-833x.2022.10.024
Six-axis free bending forming technology is a high-degree-of-freedom manufacturing technology in the field of integral forming of complex bending components. It can realize the overall accurate forming of tube components with complex axes and profile bending components with cross-sectional torsion characteristics. This article starts with the basic principles of six-axis free bending forming technology, and introduces the design of key equipment structure and the algorithm analysis of bending die movement trajectory. The method of combining finite element simulation and experiment is used to study the characteristics of the wall thickness distribution during the forming of the square tube, and the influence of the section torsion on the bending radius and bending direction of the formed member is analyzed.
2022 Vol. 65 (10): 24-33 [
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242
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FORUM
36
Study on Forming Process and Mechanical Properties of GH4068 Alloy Pipe
CUI Chuanyong，BAI Yingbo，ZHANG Rui, ZHOU Zijian，ZHOU Yizhou，SUN Xiaofeng
DOI: 10.16080/j.issn1671-833x.2022.10.036
GH4068 alloy pipes were prepared by casting directly canned hot extrusion and blooming+extrusion. The forming and service properties of the alloy pipes under two kinds of preparation conditions were studied by thermal compression simulation test and mechanical property test. The results show that GH4068 alloy has great thermal deformation ability when processed below γ′ complete solution temperature. After high-temperature annealing, the grain structure of as-cast alloy is coarse and the deformation coordination is poor. The optimum deformation temperature is higher (1130℃ ) during direct extrusion; The fine grain structure obtained after blooming is helpful to improve the deformation ability and reduce the hot extrusion temperature. The dynamic recrystallization volume fraction of the bloom alloy after deformation at 1090℃ and 0.1–1s
–1
strain rate is more than 95%. The grain size of the tube obtained by blooming+extrusion is about 6.8μm. Fine grain structure and primary γ′ phase at grain boundary contribute to the improvement of the tensile properties of the alloy, and its yield strength at 750℃ reaches 1088MPa. The existence of a large number of grain boundaries in the fine grain structure of the bloomed + extruded pipe affects the high temperature stress-rupture property of the alloy, and its endurance life is lower than that of the as-cast extruded pipe with coarse grain (about 35μm).
2022 Vol. 65 (10): 36-43 [
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256
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41
Application of Key Technologies on Manufacturing Process of Titanium Alloy Tube Assembly for Aeronautic Hydraulic Pressure System
YAN Jing，ZHANG Rongxia，WU Wei，ZENG Yuansong，ZHANG Yan，WANG Shoucai
DOI: 10.16080/j.issn1671-833x.2022.10.044
A manufacturing methodology is provided for typical titanium alloy tube assemblies in 21–28MPa aeronautic hydraulic pressure system, based on tube numerical control left/right bending technology, tube optical measurement technology, tube flareless internal rolling connection technology and quality test technology of titanium alloy tube assemblies. This methodology is verified by a manufacturing process of the high strength titanium alloy (Ti–3Al–2.5V) tube assemblies for a typical hydraulic pressure system in a commercial plane. It can be found that the manufacturing precision, efficiency, and reliabilities of the titanium alloy tube assemblies are enabled by using this methodology, and a new technology way can be found for solving the leakage problems in aeronautic hydraulic pressure system.
2022 Vol. 65 (10): 41-51/60 [
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236
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Solid Medium Forging of Impingement Cooling Pipe for Aero-Engine Blade
HAN Jinquan, WANG Shangzhao, MENG Bao, WAN Min
DOI: 10.16080/j.issn1671-833x.2022.10.052
The pipe die forging with solid-medium-filling was simulated by finite element method to the effects of parameters, such as blank size, core volume and friction coefficients, on the thickness distribution and shape accuracy. The stress–strain cures of tube blank material and core material were obtained by unidirectional tensile test and unidirectional compression test. The methods of determining the geometric dimensions of tube blank and core based on the final parts were given. The tangential parting surface was proposed in die design in order to avoid flash. According to the material data, the geometric model of tube blank, core and die, the finite element model of forming process was established. Then the processing was simulated. Taking the part thickness distribution and the gap between part and die in the simulation results as the indexes to evaluate the forming quality, the effects of the dimensional parameters of
α
and
β
and the friction coefficients f
i
and f
t
on the forming results are analyzed. The results show that the dimensional parameter combination
α
=1.00 and
β
=1.05 and the friction coefficient combination f
i
= 0.05 and f
t
= 0.05 are more conducive to the thickness distribution and shape accuracy.
2022 Vol. 65 (10): 52-60 [
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158
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61
Investigation on Flanging Process of T–Shaped Tube With 6061 Aluminum Alloy Used in Aeronautical Field
CHEN Dayong，XU Yong，ZHANG Shihong，CHENG Ming，SONG Hongwu，DENG Quanshui，HUANG Xinyue，WANG Chengcheng
DOI: 10.16080/j.issn1671-833x.2022.10.061
An efficient and low-cost forming method was explored and studied aiming at solving the problems of low efficiency and poor dimensional accuracy in traditional stamping and welding process for aluminum alloy T–shaped tube used in aeronautical field. The design of flanging process and die development of 6061 aluminum alloy T–tube were carried out by the combination of finite element simulation and experiment. The effects of three different structures of drawing heads, conical, concave conical and spherical on the forming are simulated, respectively. Meanwhile, the influence was explored for the variation of wall thickness thinning ratio of branch tube under different initial pre-hole conditions. With the help of electronic universal testing machine, the flanging force under different pre-hole conditions was accurately recorded and compared. The results show that the designed die can realize the efficient forming of 6061 aluminum alloy T–tube with branch height of 3mm, and the maximum wall thickness thinning ratio is about 33.6%.
2022 Vol. 65 (10): 61-67/88 [
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178
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Research on Deformation Law of 6061 Aluminum Alloy Tube Formed by Medium Bulging Process With Magnetic Pulse Impacting
XU Junrui，LI Yi，WANG Yuyang，ZHAO Yudong，WANG Yuanfeng，WANG Qiangkun，YAN Liangming
DOI: 10.16080/j.issn1671-833x.2022.10.068
6061 aluminum alloy tube was taken as the research object, the simulation software ANSYS was used to establish the finite element model of electromagnetic field and deformation field. The deformation laws of height variation, thickness reduction, stress and strain distribution, deformation uniformity in tube bulging process were analyzed. The results show that the serious thickness reduction and inhomogeneity of axial deformation are improved by medium bulging process with magnetic pulse impacting, and deformation contours enlarges and uniform deformation length increases compared with traditional magnetic pulse bulging. The bulging height has a linear relationship with the discharge energy. Changes of deformation uniformity is small with discharge energy at constant medium height. Medium height increases with the increase of tube deformation. Appropriate medium height can enhance the uniformity of tube, improve the sticking die at round corner and avoid medium failure.
2022 Vol. 65 (10): 68-74 [
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175
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75
Study on Push-Bending Forming of GH4169 Superalloy Thin-Walled Tube With Small Bending Radius
FANG Jizhao, GUO Wei, CHEN Genfa, YANG Pingchuan, DENG Tao, MENG Xiangnan
DOI: 10.16080/j.issn1671-833x.2022.10.075
Based on the cold expansion push-bending forming technology, the cold expansion push-bending forming die of superalloy pipe is designed and manufactured, and the deformation characteristics of 1
D
bending radius superalloy pipe are analyzed with the help of numerical simulation. The combination filling method of polyurethane with different properties is proposed, which successfully solves the collapse problem in the cold expansion push-bending forming process of superalloy pipe. Optimum process parameters of GH4169–G52×1.0 superalloy tube are obtained from three aspects: polyurethane packing, cylinder jacking pressure and lubrication conditions (friction). Accuracy of the process parameters is verified by experiments, and the engineering application of cold expansion push-bending forming of superalloy pipe is realized.
2022 Vol. 65 (10): 75-81 [
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188
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82
Research on Instability and Wrinkling Process of Viscous Outer Pressure Forming for Thin-Walled Tube Part
GAO Tiejun，REN Chenglin，LIU Lingyun，WANG Zhongjin
DOI: 10.16080/j.issn1671-833x.2022.10.082
The outer pressure forming method corresponding to the inner pressure forming of thin-walled tube parts is rarely applied to the forming of large deformation parts due to the influence of instability and wrinkling. Viscous outer pressure forming uses the physical characteristics and mechanical properties of the viscous media to not only provide the stability of the tube, but also adapt to changes in the shape of the wrinkling tube, and eliminate wrinkles under a certain pressure field, thereby effectively solve the outer pressure influence of instability and wrinkling during forming on the quality of outer pressure forming. This paper mainly introduces the basic principle of viscous outer pressure forming, summarizes the influence of medium properties, loading methods and tube size on the instability wrinkling process, as well as the application of viscous outer pressure forming in thin-walled tube parts, and summarizes and looks forward to the existing problems and development trends.
2022 Vol. 65 (10): 82-88 [
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161
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89
Thread Grooving Deformation and Defect Analysis of Thin-Walled Tubes During Incremental Forming
TANG Haoxing，YANG Fan，LU Shenghai，LIU Longqin，ZHOU Yin，ZHENG Yu，WEN Tong
DOI: 10.16080/j.issn1671-833x.2022.10.089
According to the principle of single-point incremental forming, experiment and numerical simulation were employed to study the deformation features, thickness distribution and springback during incremental thread grooving on thin-wall tubes, where Al6061 tubes with outer diameter of 38mm and thickness of 1mm were used. The wall thickness variation was discussed by using Glock’s hinge model, and the effects of groove depth, spacing and feed rate on springback were clarified. Results show that incremental tube grooving on tubular parts can meet the demand of flexible manufacturing, and the errors of groove spacing between the experiment and expectation are within 6%. With the groove depth increasing, wall thinning intensifies, but due to the hinge effect the bottom wall thickness may increase. The springback of tube wall increases with a deeper groove and a larger single step size of tool head, the springback decreases about 40.2% when the single step size is 0.25mm compared with 1.5mm. In addition, the materials near the grooves may deform repeatedly and the local structural stiffness will improve under a small groove spacing (Δ
l
), which can inhibit springback, the springback decreases about 38.5% when Δ
l
is 10mm compared with 50mm.
2022 Vol. 65 (10): 89-93 [
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157
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RESEARCH
94
Research on High Effciency Machining of Titanium Alloy Integral Structural Parts With Large Depth-Width Ratio
MU Jianwei, LI Liangliang, SUN Guoyan
DOI: 10.16080/j.issn1671-833x.2022.10.094
In the context of the manufacturing process of some essential parts of advanced fighter aircraft, the task of process planning, as well as the concern of efficient and accurate machining for titanium alloy integral structural parts with large depth-width ratio, acts as a major bottleneck. In this paper, based on the analysis of the material characteristics and structure features of the integral wing rib, coupled with the analysis of its corresponding machining difficulties, the overall efficient machining process route is firstly formulated, which entails the collaborative manufacturing of three-axis machine tool and five-axis machine tool. The clamping points are thus determined by considering the characteristic of variable stiffness. On account of the characteristic of small curvature of the cutting area, the machining strategy with the conditions of constant angle and large side-step upheld is adopted. Aiming at the existing problems of chatter of the deep cavity machining and low efficiency, a rigidity and stability oriented layered milling method is thereby proposed. With the demand of precise weight, an additional angle assisted precision machining method for narrow angle without uncut material is then presented. Finally, the parts quality and machining efficiency are guaranteed by adopting the aforementioned methods, thus providing technical support for the mass production.
2022 Vol. 65 (10): 94-97 [
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166
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98
Development Method and Software Realization of Invar Alloy Mould Plate With Double Curvature
LI Yuyang，JI Wen，ZHANG Likang，GUO Qiqi，HU Yong，HUANG Chaoyan
DOI: 10.16080/j.issn1671-833x.2022.10.098
The unfolding accuracy of Invar alloy mould plate with double curvature has an important influence on the accurate cutting of the workpiece and the amount of machining work after pre-forming. Based on the study of forming process and deformation distribution of hyperbolic sheet, a development method for the plate with double curvature based on small triangle is proposed. The surface is divided into several strips and small triangles, and then the small triangles are unfolded and spliced to get the unfolded shape. The key is the splicing method and the treatment of overlapping and gap. On this basis, the development software is developed and verified in actual production. Based on the development processing of 121 plates in 32 sets of dies, it is found that only 5–10mm allowance is needed for the workpiece processed by this method, which is far less than the 20–40mm allowance required by the traditional development method, which can significantly reduce the subsequent machining workload.
2022 Vol. 65 (10): 98-103 [
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208
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104
Pulsating Assembly Line Planning and Workshop Layout Design of Civil Aircraft Nose System
FENG Yiming，JIANG Nan，LI Bo，LI Shaobo，WANG Yan，WANG Wei
DOI: 10.16080/j.issn1671-833x.2022.10.104
Pulsating assembly line is a new aircraft assembly organization mode, which can effectively shorten the aircraft assembly cycle and improve the assembly quality and efficiency. At the same time, the task modularization division of aircraft nose system integration is in line with the idea of modular design of pulsating assembly line, which has the basic conditions of pulsating assembly. In order to improve the integration efficiency of aircraft nose system, this paper takes a certain type of aircraft nose system as the research object, analyzes the specific assembly process of modular delivery, divides stations and determines pulse takt time based on assembly sequence constraints, and optimizes it with the ECRS (Eliminate–combine–rearrange–simplify) analysis method. Based on the system layout design (SLP) method, the specific idea of workshop layout design of head pulsation assembly line is put forward. Finally, the load balanced station setting and reasonable logistics workshop layout scheme are given, which provide support for civil aircraft to further carry out the research on pulsating assembly lines of various nose systems.
2022 Vol. 65 (10): 104-112 [
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231
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113
Design and Calibration of Visual Inspection Tool for Welded Pipe Flange End Face
LUO Yijin, Lü Zhengyang, ZHANG Liyan
DOI: 10.16080/j.issn1671-833x.2022.10.113
In order to obtain the installation posture of flange end faces in multi-branch welded pipelines quickly and accurately, a flexible measurement tool, together with a calibration procedure, is proposed for visual inspection. Each flange end face is fxed by the measurement tool’s claw, whose scalability could adjust to various types of pipelines with different diameters. In addition, the measurement tool possesses a good self-centering capability. A number of visual target points are laid on the bottom of the measurement tool. By visually measuring the target points on the calibrated measurement tool, a measurement coordinate system can be built up, which could represent the normal vector, the location of center point and circumferential position of the flanges. The experiments show that the absolute location accuracy of the flanges end faces is 0.070mm, and the double standard deviation of repeated positioning is 0.044mm.
2022 Vol. 65 (10): 113-120 [
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174
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