三维复杂异形截面构件自由弯曲成形机理及缺陷调控研究

Aiming at the important requirement of space station, satellite, launch vehicle and other space equipment for three-dimensional complex special-shaped cross-section components, a new method of three-dimensional free bending forming is proposed, which breaks through the limitations of traditional die forming methods, and solves the problem of precise integral forming of three-dimensional special-shaped cross-section components. This project firstly intends to study the formation mechanism of bending axes of three-dimensional components, construct a theoretical model of bending radius-bending die offset (R-U) relationship under the condition of continuous variable curvature, and reveal the optimization of bending mode trajectory and the precise compensation method of springback. Secondly, the global sensitivity analysis method will be used to find out the key factors and influencing rules of non-uniform deformation of special section, and to reveal the multi-parameter coupling mechanism of uneven deformation. Finally, based on the principle of minimum energy, the numerical prediction model of component plastic instability and the theoretical calculation model of forming limits will be established to reveal the main forms and formation mechanism of forming defects, and to study the parameter optimization method aiming at controlling forming defects and improving forming limits. This research is of great scientific significance and engineering value to break through the bottleneck of precise forming of complex components for space equipment, improve the overall manufacturing level of three-dimensional complex components for aerospace and ensure the development cycle of aerospace equipment, space utilization and system functionality.

针对空间站、卫星、运载火箭等航天装备对三维复杂异形截面构件的重要需求，提出三维自由弯曲成形新方法，突破传统依靠模具成形方法的局限性，解决三维异形截面构件整体精确成形的难题。本项目拟系统研究三维构件自由弯曲轴线形成机理，构建连续变曲率条件下的弯曲半径-弯曲模偏距(R-U)关系理论模型，揭示弯曲模运动轨迹优化及回弹精确补偿方法；探明异形截面不均匀形变的关键因素及影响规律，揭示不均匀形变的多参数耦合作用机理；基于最小能量原理，建立构件塑性失稳数值预测模型及成形极限理论计算模型，揭示成形缺陷的主要形式及形成机制，研究以控制成形缺陷、提高成形极限为目标的参数优化方法。该研究对突破航天装备复杂构件精确成形的瓶颈，提高航天三维复杂构件的整体制造水平，保障航天装备的研制周期、空间利用率、系统功能性等方面具有重要的科学意义和工程价值。

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