Secondary Development Of One-step Forming Springback Compensation Mold Profile Generation Software

One-step forming is one of the forming methods for the manufacturing of aircraft sheet metal parts.Rubber forming parts account for more than 50% of the total number of aircraft sheet metal parts.Springback is the main defect of rubber forming.In order to improve the rubber forming efficiency of sheet metal parts,for the rebound problem,this paper studies the forming properties of as-quenched materials from the perspective of influencing the springback factors,and established the springback theoretical model.The key technologies such as finite element numerical simulation technology and secondary development of springback compensation system are applied to solve the springback problem of the rubber forming process,improve the production level,and realize the precise manufacturing of the one-step forming process.The mechanical properties of the aluminum alloy material in the as-quenched state were tested.The variation of the forming parameters of the forming parameters was studied.The material parameter database was established.The database was connected with the material parameter window of the springback compensation module through secondary development.The reading and writing of material parameters are realized;the constitutive model parameters of the aluminum alloy material in the as-quenched state are obtained,which lays a foundation for the subsequent finite element simulation and springback compensation.The typical feature parts in the rubber forming process are analyzed.Combined with the theoretical springback compensation algorithm,a normal plane of the curve compensation method is proposed in this paper.Through the secondary development of CATIA CAA,the cross-section curves of the digital part of the rubber-formed sheet metal parts and the section of the flange are compensated,and the multi-section surface method is used to generate the compensation surface,thereby forming a springback compensation system,the rubber forming springback dies can be compensated rapidly and precisely.The finite element model was established.The PAMSTAMP software was used to verify the compensation of the springback compensation system.The stress,strain,displacement and springback distribution of typical rubber-formed parts were analyzed to verify the accuracy of the analysis model.Finally,the typical straight flange,convex flange,concave flange,jogged and hole flanged rubber forming parts are used,and the secondary development of the springback compensation software is used to produce the compensation dies.The rubber forming was formed on the QFC1.4X4-1000 rubber hydraulic machine,and the springback deviation of the formed parts was within ±1°,meeting the tolerance requirements of the aviation standard HB6470-1990.The accuracy and practicability of the springback compensation system are verified,which has a good application value in the one-step precision forming manufacturing of aircraft sheet metal parts.