Research On The Manufacturing Technology Of Titanium Alloy Honeycomb Cores

Honeycomb sandwich structure has been widely used in aerospace field for its excellentproperties such as low density, high specific strength and thermal insulation. With the development ofthe aerospace technology, there are increasely high demands for the lightweight and high temperatureresistant properties of honeycomb structures nowadays. To meet these requirements, the titaniumalloy honeycomb structure has been developed. However the domestic research on titanium alloyhoneycomb started late and its processing technology is not mature, which hinder of its application inthe Chinese aerospace industry to some extent. To further address the titanium honeycombmanufacturing process, this project utilized the TC1titanium alloy to manufacture the honeycombstructures and the test measuring analysis has done for the its connection performance.The honeycomb core was made by the molding method according to the titanium materialproperties. First, the forming process of corrugated board was analyzed based on plastic bendingsheet metal theory, and a gear unit with a distortion mold for forming corrugated board was designedand optimized to get qualified corrugated board. Secondly, the dynamic simulation of corrugatedsheet metal forming process based on Ansys/Ls-dyna commercial software was conducted andparametric design of the simulation model was achieved by using the APDL language. The simulationresults were compared with the experimental results to verify the feasibility of the finite elementmodel. Then the connection properties and weld organization of corrugated boards were observed andanalyzed by metallographic experiments, and the shear strength and pulling strength of solder jointswere measured by tensile tests. Finally, the wire-electrode cutting and high-speed grinding were usedfor the face machining of the honeycomb core, and the gypsum holding process was proposed to holdthe honeycomb core in grinding process was proposed.The research on the corrugated boards was conducted in terms of the development of the theoryof forming the corrugated boards, the design of roll forming equipment, the spot welding processesand the welding properties analysis, and the retaining methods in machining process, which carriesboth innovative and practical value. Ultimately a high performance titanium honeycomb core wasmanufactured based on the above mentioned researches, which provides the basis for the manufactureand application of titanium honeycomb.