| Al-alloy integral panels have been widely used in aerospace industry due to theiradvantages of light weight, high strength, high efficiency, high reliability and goodsealing. The forming quality of integral panel depends on the processing parameterswhich are usually determined by the workers’ experience. The forming process needsa lot of repeated tests and amendments wasting a great deal of manpower and materialresources. The finite element simulation of metal forming process can predict possibledefects occurred during process in order to enhance productivity and reduce cost. Inthe present study, the roll bending process and the effect of fillers on forming qualityis investigated by finite element simulation under the ANSYS/LS-DYNAenvironment. Three-dimensional FE models are performed based on the explicitdynamic finite element method in simulation process. The main conclusions include:(1) Parameters of meshing, length of panel and loading speed for the simulationare estimated by test calculations and theoretical analysis, which have obtainedaccurate simulation results and improved computational efficiency. The method fordetermining the panel’s length could be applied to predict the springback of integralpanel roll bending process.(2) Based on the comparison of the effects of adopting fillers with differenthardness and thickness on roll bending process of2219Al-alloy integral panel, thefollowing conclusions can be drawn: higher hardness and thickness could get betterimprovement for generatrix linearity, residual stress and deformation homogeneity.(3) In the condition of using best filler process got from last step, the result ofsimulation of deforming integral panel adopting four-roller roll bending process iscompared with the result of three-roller roll bending process. It’s concluded that theintegral panel gets better improvement in generatrix linearity, residual stress anddeformation homogeneity using four-roller roll bending process. |
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