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Advances and challenges on springback control for creep age forming of aluminum alloy

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Chinese Journal of Aeronautics 2022年第10期35卷 8-34页

作者： Liwen ZHANG Heng LI Tianjun BIAN Changhui WU Yang GAO Chao LEI Taicang Yangtze River Delta Research Institute of NPU Northwestern Polytechnical UniversityTaicang 215400China State Key Lab of Solidification Processing School of Materials Science and EngineeringNorthwestern Polytechnical UniversityXi'an 710072China Shanghai Aerospace Equipments Manufacturer Co. Ltd.Shanghai 200245China School of Materials Science and Engineering Xi'an University of TechnologyXi'an 710048China

Creep age forming(CAF)is an advanced forming technology that combines creep deformation and age hardening *** compared with the conventional forming technologies including roll bending and shot-peen forming,CAF has many advantages of low residual stress,excellent dimensional stability,good service performance and short production *** is an optimal technique for precise manufacturing for shape and properties of large-scale complicated thinwalled components of light-weight and high strength aluminum alloys in the aviation and aerospace ***,CAF has an inevitable disadvantage that a large amount of springback occurs after unloading,which brings a challenge on the accurate shape forming and property tailoring of ***,how to achieve accurate prediction and control of springback has always been a bottleneck hindering the development of CAF to more industrial *** the factors of affecting springback and measures of reducing springback are summarized from the internal and external aspects,constitutive models for predicting springback and springback compensation methods for CAF of aluminum alloy panel components are ***,a review of research progresses on tool design for CAF is ***,in view of the key issue that it is difficult to predict and control the shape and properties of components during CAF,the technical challenges are discussed and future development trends of CAF are prospected.

关键词： Aluminum alloy Creep age forming Integrated manufacturing Springback compensation tool design

Radial envelope forming mechanism and process design method for cylindrical rings with thin wall and high web ribs

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Chinese Journal of Aeronautics 2023年第12期36卷 461-476页

作者： Xinghui HAN Yanlei MIN Wuhao ZHUANG Lin HUA Duanyang TIAN Zushen DENG Ningbo LIU Hubei Key Laboratory of Advanced Technology for Automotive Components Wuhan University of TechnologyWuhan 430070China Hubei Longzhong LaboratoryXiangyang 441000China

Cylindrical rings with thin wall and high web ribs(CRTWHWR)are widely used as the key load bearing structures such as rocket body and space station cabin in aerospace ***,it is still difficult to efficiently manufacture CRTWHWR with high performance because of their extreme geometry with thin-walled skins,high web ribs and large *** this paper,a novel radial envelope forming process is put forward to efficiently achieve the plastic forming of CRTWHWR with high ***,the principle of radial envelope forming process is ***,an efficient design method for the tool motion and geometry is proposed based on the reverse envelope principle,i.e.,CRTWHWR is adopted to reversely envelope the tool and thus the tool which does not interfere with CRTWHWR can be efficiently obtained in a single ***,a reasonable 3D FE model of the radial envelope forming process of CRTWHWR is established and the radial envelope forming mechanism of CRTWHWR is comprehensively *** the FE simulation and experiments with material of plastic mud,a typical CRTWHWR with diameter of 300 mm,axial height of 192 mm,the maximum rib height of 25 mm,the minimum rib thickness of 3 mm and skin thickness of 5 mm is radial envelope formed,i.e.,the ratio of the maximum rib height to the minimum rib thickness reaches 8.33,the ratio of the maximum rib height to skin thickness reaches 5 and the ratio of diameter to the minimum rib thickness reaches *** above results verify that the proposed radial envelope forming process has great potentials in efficiently manufacturing CRTWHWR with extreme geometry.

关键词： Radial envelope forming Cylindrical ring with thin wall and high web ribs Forming mechanism FE simulation tool design

Recent progress in friction stir welding tools used for steels

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Journal of Iron and Steel Research International 2018年第5期25卷 477-486页

作者： Lei Cui Chao Zhang Yong-chang Liu Xiu-guo Liu Dong-po Wang Hui-jun Li Tianjin Key Laboratory of Advanced Joining Technology School of Materials Science and Engineering Tianjin University Tianjin 300354 China State Key Lab of Hydraulic Engineering Simulation andSafety School of Materials Science and Engineering TianjinUniversity Tianjin 300354 China Faculty of Engineering and Information Sciences Universityof Wollongong Wollongong 2522 NSW Australia

Friction stir welding （FSW） technology is being increasingly attractive in welding steels on account of the high-quality weld formation and excellent weld properties. The feasibility of FSW of steels has been convinced for nearly 20 years. However, the application progress for FSW of steels is slower than that of aluminum alloys owing to the high cost and poor usability of tools. The FSW tools are called as the heart of FSW process which is critical for welding quality control and the weld microstructure and properties. The recent progresses in research and development of FSW tools for welding steels have been reviewed. Material selections, geometry parameters, wear behavior and use life of the tools are summarized from the available literatures.

关键词： Friction stir welding Steel FSW process tool material tool design tool wear behavior

Process forces and heat input as function of process parameters in AA5083 friction stir welds

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Transactions of Nonferrous Metals Society of China 2012年第2期22卷 288-298页

作者： Rajneesh KUMAR Kanwer SINGH Sunil PANDEY Engineering Division National Metallurgical LaboratoryJamshedpur 831007India Mechanical Engineering Department Indian Institute of Technology DelhiDelhi 110016India

AA5083 friction stir welds were produced using systematic experimental design, the process forces and heat input with varying parameters were studied. Helpful empirical models were developed in designing friction stir welding （FSW） tools and FSW welders. These models may be further helpful for making process parameter choice for this sort of alloy, defining welding program and control of process parameters by using computer numerical control friction stir welding welders. The results show that tool rotational speed, welding speed and tool shoulder diameter are most significant parameters affecting axial force and heat input, while longitudinal force is significantly affected by welding speed and probe diameter.

关键词： friction stir welding AA 5083 tool design heat input process forces process parameters