| With the continuous improvement of the demand for automotive performance,vehicle emission standards,and the continuous development of new energy vehicles,automobile lightweighting has received more and more attention.The use of new lightweight materials is one of the effective methods for lightweighting of automobiles.At present,aluminum alloys and composite materials are the main materials for lightweight vehicles,and the combination of the two can maximize the performance of each use while saving costs.However,for the co-curing method of aluminum alloy and composite material,some metal-composite co-cured members may cause deformation of the composite part after finishing.In addition to the poor quality of the component itself,when such a deformed component is assembled with other components,the assembly stress generated by forcing the assembly greatly increases the risk of component failure.Aiming at the above problems,this paper takes a metal-composite co-cured profiled component as the research object,and explores the processing deformation control method of the component.(1)It is known by consulting the literature that the processing deformation of the research object is caused by the residual stress inside the composite material and the weak rigidity of the metal shell.Aiming at the residual stress inside the composite,the causes and related measurement methods are introduced.The test principle of the cutting method and the residual stress calculation method based on the test data are introduced in detail.(2)The elastic modulus of the composite was measured by tensile test.The incremental cutting test was carried out on the metal-composite co-cured plate.The residual stress of the composite was calculated according to the test results.The Legendre polynomial pair was used.The residual stress is fitted and the best fitting order of the Legendre polynomial is determined by the uncertainty calculation.The residual stress distribution inside the composite was obtained.(3)Considering the processing deformation control method from the perspective of the external composite material and the internal metal casing.From the perspective of composite materials,the stress calculation results are numerically simulated as pre-stress.The numerical simulation method is used to verify that the pre-machined stress relief groove can reduce the deformation of the component and parameterize the stress relief groove.Then,the application test of the stress relief groove is carried out on the profiled member.The test results show that the process of pre-processing the stress relief groove does not cause excessive processing deformation of the component and can effectively release part of the residual stress.From the perspective of the metal shell,the proposed method of controlling the machining deformation by increasing the rigidity of the metal shell is verified by numerical simulation. |
