锻压技术

2195铝锂合金非等厚壁板增量压弯成形工艺裂纹分析与结构优化

英文标题：Crack analysis and structural optimization on incremental press bending process for non-uniform thickness plate of 2195 aluminum-lithium alloy

作者：陈乐乐1 胡德友1 南康斌2 韩运奇2 娄淑梅2 初冠南3

单位：1.天津航天长征火箭制造有限公司 2.山东科技大学智能装备学院 3.哈尔滨工业大学（威海）材料科学与工程学院

关键词：2195铝锂合金非等厚壁板增量压弯成形裂纹应力集中

分类号：TG386

出版年,卷(期):页码：2025,50(7):67-73

摘要：

针对2195铝锂合金非等厚壁板增量压弯成形过程中，在凸台、孔洞与筋条三者交汇处出现的裂纹，通过ABAQUS进行有限元分析，确定开裂原因为剪切力引起的剪切变形，并且由于断裂位置处的应力状态为三向拉应力，从而加速了壁板的断裂。根据模拟结果及生产条件，提出通过坯料凸台过渡处蒙皮的厚度渐变来缓解过大的厚度差异带来的应力分布不均和剪切塑性变形，增强该区域的结构强度和稳定性，进而降低因应力集中而导致的断裂风险。利用ABAQUS对优化方案进行有限元分析，发现优化后的Mises等效应力、正应力和剪切应力的分布更为均匀，优化后原裂纹位置处的应力明显减小，材料的抗裂性能得到了有效提升，可以加工出满足要求的产品。

For the cracks occurred at the intersection of bosses, holes and ribs in the incremental press bending process for non-uniform thickness plate of 2195 aluminum-lithium alloy, the finite element analysis was performed by ABAQUS, and it was determined that these cracks were generated by the shear deformation caused by shear force and the stress state at the fracture location was triaxial tensile stress, which accelerated the fracture of the plate. Then, based on the simulation results and production conditions, it was proposed to alleviate the uneven stress distribution and the shear plastic deformation caused by excessive thickness differences through a gradual thickness transition in skin at the blank boss interface, which enhanced the structural strength and stability of this area and reduced the fracture risk caused by stress concentration. Furthermore, the optimized scheme was subjected to finite element analysis by ABAQUS. The results show that the distributions of Mises equivalent stress, normal stress and shear stress after optimization are more uniform. The stress at the original crack location is significantly reduced, the crack resistance of the material is effectively improved, and the products meeting the requirements are processed.

基金项目：

作者简介：陈乐乐（1986-），女，硕士，工程师 E-mail：chenlele86@126.com 通信作者：娄淑梅（1979-），女，博士，教授 E-mail：msl7119@163.com

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