面向超大型高精度曲面的夹层结构面板超精密成形及型面精度调控

Extra-large high-precision curved surface (The area is above 300 square meters and the accuracy is better than 40 microns) is the key of extra-large compact antenna test range（CATR）reflector used for full-size target stealth test. This reflector is generally constituted by dozens of high-precision panels with different geometry. The area and RMS (Root Mean Square) of one single panel are more than 6 square meters and better than 20 microns respectively. So this panel is difficult to be formed because surface accuracy with micron level will be realized in area with square meter level. Theory of ultra-precision forming, accuracy prediction and shape adjustment in manufacturing extra-large sandwich panel will be investigated. The rapid theoretical modeling for forming processes of large sandwich panels will be established. The forming process and springback behavior of sandwich panels with heterogeneous material under complicated contact will be simulated accurately. Micro deformation under multi-point adjustment will be predicted and controlled accurately. The influencing factors of slicing in integral forming of extra-large high-precision panel will be studied and slicing guideline will be established. The effect of non-uniform distortions during the forming on fit between panel and die will be studied. Micro Springback prediction and compensation of extra-large and high-precision sandwich panels in ultra-precision forming will be achieved. Multi-point shape adjustment technology will be developed to further improve the accuracy of large surface. The forming theory of high-precision panel will be developed and the problem of extreme manufacturing with large curved surface in micron accuracy level will be solved.

超大型高精度曲面是建造全尺寸目标隐身测试装备（超大型紧缩场反射器）的基础，面积达300平方米以上，型面精度要求优于40微米，由几十块形状不一的高精度面板拼装而成，单块面积尺寸大（6平方米以上）、型面精度要求优于20微米，达0.01毫米量级，难度极大，属超大面积微米级极端成形制造范畴。针对轻质夹层结构超大型高精度面板，研究其超精密成形理论、精度预测与调控方法，突破超大尺寸夹层板成形快速分析理论建模、异构材料夹层板复杂接触约束下成形过程与回弹行为高精度仿真、多点微调型面微细变形精确预测与调控等关键问题。理论解析、数值模拟与试验相结合，研究超大型高精度面板整体成形分块拼接影响因素并建立分块准则，揭示成形过程中非均匀扭曲变形对贴模精度影响规律，实现大面积高精度夹层板超精密成形回弹预测与补偿，建立提高型面精度的多点微细调控方法。发展超大型曲面微米级极端成形制造理论，解决超大尺寸高精度面板制造难题。

超大型紧缩场、近场测试系统是发展隐身和反隐身技术，实现飞机、舰船、导弹等隐身武器装备散射特性测量的必备设施。而超大型高精度面板的超精密成形制造是限制建造超大型紧缩场、近场亟需突破的瓶颈技术。针对超大型高精度曲面夹层面板超精密成形难题，研究并发展了超大尺寸夹层结构面板超精密成形理论和精度微细调控方法，为我国隐身测试装备高精度极端制造技术自主可控提供了创新理论，解决了超大尺寸高精度面板制造难题。.项目开展了夹层结构面板超精密成形理论及力学建模、超大型曲面分块拼接影响因素分析、成形各工艺参数对贴模精度的影响、夹层结构面板结构刚度评估及回弹预测、基于多点微细调控的型面精度调节方法和应用验证实验等方面的研究。建立了一套超大型高精度曲面夹层结构面板的超精密成形理论及精度调控方法，实现了单块6平米及以上超大型高精度面板的超精密成形，型面精度RMS达到20~30微米量级，获得的超大型高精度面板具有精度高、稳定性好等优点。项目研究成果丰富和发展了超大型曲面微米级极端成形制造理论，同时，取得的理论研究成果和突破的核心关键技术，成功应用于我国自主研制的静区10米以上超大型紧缩场、工作频达110GHz高性能紧缩场以及静区达30米近场的建造。具体研究工作如下：.通过理论解析研究了超大型夹层结构面板超精密成形理论，提出了超大型夹层结构面板超精密成形及回弹预测的快速建模方法；利用理论解析和数值模拟相结合的方法，研究了硬板面内应力水平和局部受压失稳对分块尺寸的影响规律，建立了分块拼接临界尺寸控制曲线；研究硬板贴模临界压力与面板几何参数之间的关系，获得了面板几何参数对其贴模精度的影响规律；通过建立基于临界贴模压力的外力法回弹预测模型，研究了相对拱高对临界模压、贴模精度、型面精度的影响规律，获得了型面精度与相对拱高、缝隙系数、面板厚度之间的关系；利用有限元分析方法，研究了夹层结构面板多点型面调节关键点位置及数量的优化方法，获得了各调节点之间的相互作用规律，设计开发了超大型高精度面板型面调节实验平台，开展了型面微细调节实验；研究获得的理论成果和突破的核心关键技术，成功应用于某超大型紧缩场、近场超大型高精度反射面的研制，近400平米的反射面整体型面精度RMS达40~50微米量级。.项目培养博士生2人，硕士生7人，已毕业5人；发表论文9篇，其中SCI检索2篇，EI检索2篇；申请发明专利7项，其中已授权3项。