纤维增强金属层板热介质制备成形一体化技术基础理论研究

Fiber Metal Laminates (FMLs) is a new kind of lightweight composite material that is becoming increasingly popular in aeronautical, automobile and military industries. The FMLs structures are used to replace metals and alloys for additional weight reduction, strength and fuel economy .Presently, due to the limitation of the current forming techniques, the object of fabricating mass-produced FMLs components with high quality and high efficiency has not been fulfilled, which greatly hampers the widely application of this lightweight material. Now FMLs structures are made with relatively simpler shapes and larger radius profile curves such as fuselage or doors and usually have high cost and long production phase. This proposed project aims on hot medium forming technique of FMLs using heated medium instead of rigid molds, breaking through the limitation of the conventional forming process of FMLs and finally mastering the integrated technology of preparing and forming FMLs while obtaining high precision shape dimensions. The research will be focused on the key scientific problems in the process of theoretical analysis and finite element analysis including the fabrication of smaller and complex shaped FML parts, investigating the material preparation, forming process parameters, the forming limits, fracture criteria, damage evaluation of the fiber metal laminates, the inner microstructure evolution and its influence rules under thermal and fluid pressure effects. Furthermore, the mechanical behavior of FMLs material under hot medium forming process will be investigated comprehensively and extensively. This proposed new method would be very important for reducing production cost, enhancing quality for hi-tech FMLs parts and further promoting the applications of lightweight fiber metal laminates components China.

纤维增强金属层板是一种新型的轻量化复合材料，在航空航天领域应用日渐广泛，但是，由于现有成形工艺无法满足纤维增强金属层板复杂结构件的批量化、高品质、高效率加工要求，严重阻碍了该轻质材料的推广应用，目前仅应用于具有大轮廓曲线及简单结构特征的飞机、汽车零件，价格昂贵并且加工周期长。本项目旨在结合板材热介质成形技术的优势，突破纤维增强金属层板常规成形工艺限制，在保证零件曲面精度的前提下，研究纤维增强金属层板制备成形一体化技术，并解决理论分析及数值模拟中关于纤维增强金属层板成形极限、断裂判断和损伤评估方法、热影响及流体压力作用下内部组织演化及其影响规律等关键科学问题，进一步探索在热介质成形工艺下材料的变形规律，对于降低生产成本、进一步推进纤维增强金属层板轻量化零件在我国的推广应用具有重要的实用价值和科学意义。

纤维增强金属复合材料，是由金属和纤维增强材料组成的一种新型复合结构材料。为了解决传统成形工艺的诸多的限制，提出纤维增强金属复合材料制备及热介质充液成形新技术。以纤维增强金属复合材料充液成形工艺理论为基础，针对纤维夹层增强金属复合材料的特点，主要研究断裂失效机理及纤维层板与金属层板耦合作用下复合层板成形极限表征，损伤模型评估等分析测试方法；基于基本力学试验与成形试验过程，掌握纤维增强金属复合材料的流动规律，层板各向异性以及成形极限曲线表征参数等；建立纤维夹层增强金属复合材料热介质成形力学模型与仿真模型，获取热力耦合面力加载条件下，考虑微观参量表征的纤维夹层增强金属复合材料统一本构模型以及内部组织变化对断裂准则的影响规律；完成纤维增强金属层板典型零部件的试验试制，验证并修正基础理论研究结果，提高材料力学表征模型准确度。与数值模拟相辅相成，相互验证，确定最优的工艺路线，提高成形性能，缩短生产周期，降低生产成本，最终实现改善产品质量和精度的目标。

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