Study On Monolithic Forming Technology For Aldural Complex Rib-web Component

With the development of lightweight and high performance for new equipment, Complexaldural rib-web components were widely used in modern equipment manufacturing industry.The components have complex geometry, asymmetric shape and internal reinforcement rib,whose cross section size is not uniform, the difference of web and thin wall thickness is large.Plastic forming of such components is difficult, defects such as folding, filling disaffectionwere often exists; The low plasticity of forming process, narrow temperature range, internaldefects, cause ther aldural processing and manufacturing were difficult. Therefore, an urgentneed to adopt the monolithic plastic forming technology to break through such componentmanufacturing bottleneck, meet the needs of equipment manufacturing lightweight.In this paper, using the finite element numerical simulation combined with plastic formingtheory, the metal flow characteristics of aldural complex rib-web component forming processwere studied. The distribution and change rule of physical fields such as strain, load were alsostudied;Research the influence with different preform structure parameters for the shape ofthe blank; Monolithic forming process of material flow model is established. Study thematerial flow pattern of different stages; The material flow model mechanics in differentregions was analyzed. The main stress method was used to establish the axial divided flowforming radius calculation formula; The formula of unit forming force on axial divided flowforming was derived;Extraction and build V and L-type structure model, study the materialflow characteristics, the forming process mechanics of deformation zone was analyzed, studythe different process parameters and structure parameters on the load and the influence offlow law of material forming process; Study the V-shaped component folding defects formation mechanism, established a V-shaped component folding limit diagram, studied theinfluence on folding limit with different V-shaped structure parameters;Summarized thestructural parameters of aluminum alloy L-shaped stiffened plates design criteria.Study the preformed blank structure parameter optimization method: based on theexperiment design and response surface method, with the deformation uniformity andmaterial utilization efficiency, the final forming load as the goal function, use the preformstructure parameter as design variables, target response for prediction model was establishedand the relationship between the design variables, scope of optimization design to obtaincorresponding target variable. Build the typical mathematical model of multi-objectiveoptimization problem, solve out the preforming size after multi-objective optimization;Obtain optimized preform structure parameters and the optimal solution of the objectivefunction: deformation uniformity is increased by7%, utilization rate of materials increased by6%, eventually forming load of was reduced by7%.Proposed the new monolithic forming technology for aldural complex rib-webcomponent, Through optimizing design preform structure parameter and control materialsdivided flow forming, make the blank material always exists divided flow in the process offilling cavity shunt, reduce the forming load above60%.By optimizing divided flow formingkey process parameters, avoid the forming defects such as folding and underfilling defect.Successfully trial production aldural complex components using the new monolithic formingtechnology, The comprehensive mechanical performance is increased by10%more thanconventional forming, fully meet the requirements of equipment service index condition.The research results provide theory and experimental basis for precision forging of alduralcomplex rib-web component, which provides important directive significance to production.