Formation mechanism and elimination method for surface groove of the hollow lattice structure by superplastic forming

Yanhong Mu, Zhiqiang Li, Bing Zhao, Feng Yang, Ning Zhang, Lihua Du, Yong Li
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Abstract

Abstract. The titanium alloy hollow lattice structures can be widely applied on the advanced aircrafts due to their excellent mechanical properties and light weight. Superplastic forming and diffusion bonding (SPF/DB) process is an advanced process to manufacture these hollow lattice structures with two outer plates and one inner hollow plate. To further decrease the weight of the structures, thinner outer plate is preferred when compared with the inner plate, however, it would result in the occurrence of surface groove at the intersects between the outer plate and the hollow stiffener during superplastic forming process, leading to the failure of the structures. In this paper, the formation characteristics of the surface groove and the influence of the outer/inner sheet thicknesses on the occurrence of surface grooves was investigated through a well-developed finite element model. Furthermore, an innovative method was presented to eliminate the surface groove during SPF/DB, which makes use of double-sided dynamically adjusted gas pressure on the inner and outer of the plate during superplastic forming process. Based on the developed numerical models, the effects of assistant outer gas pressure parameters on groove formation have been investigated. The effectiveness of the proposed new forming method and the optimized parameters have been validated by performing a SPF/DB forming tests of a typical lattice structures. The method developed in this study provides a new way to improve the forming quality and accuracy of hollow parts by SPF/DB.
超塑性成形中空晶格结构表面沟槽的形成机理及消除方法
摘要钛合金空心点阵结构以其优异的力学性能和重量轻的特点在先进飞机上得到了广泛的应用。超塑性成形和扩散键合(SPF/DB)工艺是制造这些具有两块外板和一块内板的中空晶格结构的先进工艺。为了进一步减轻结构的重量,外板比内板更薄,但在超塑性成形过程中,外板与空心加强筋相交处会出现表面沟槽,导致结构破坏。本文通过完善的有限元模型,研究了表面沟槽的形成特征以及内外板厚度对表面沟槽发生的影响。在此基础上,提出了一种利用超塑性成形过程中双面动态调节板内外压力的方法来消除SPF/DB过程中的表面沟槽。在建立的数值模型的基础上,研究了辅助外部气体压力参数对沟槽形成的影响。通过典型晶格结构的SPF/DB成形试验,验证了新成形方法和优化参数的有效性。该方法为提高空心件的成形质量和精度提供了一条新的途径。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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