耦合多源制造误差的航空复材与金属构件装配变形预测及形性协同控制

According to the urgent requirements of high assembly accuracy and long service life in aerospace field, and the continuously enlarging application range of composite materials, the deformation value and the stress level must be controlled strictly in assembly of composite and metal components. However, the existing methods are mainly used to ensure the geometric accuracy of structure, while the physical performance is seldom considered after assembly. And the composite components have low forming accuracy, and oversize tolerance and secondary damage are easy to appear under the assembly load. Therefore, by mean of characterization and modeling methods of manufacturing error, this project intends to build a digital assembly model, which couples the manufacturing errors of composite and metal components, and positioning error. A numerical method is developed to predict the high-performance assembly of composite and metal components. The deformation prediction, stress-damage analysis, and shape and property collaborative control technology are also been studied under the mixing constraints of process and geometric. The deformation transfer and stress evolution and their interaction mechanism are revealed under multiple source manufacturing errors and complex assembly loads. The main factors and its’ influence law on the assembly performance are also studied. The trade-off mechanism of deformation-stress is explored under force-displacement hybrid constraints, and an intelligent algorithm is used to optimize the problem. Furthermore, some typical component experiments are carried out. The purpose of this project is to provide theoretical support and technical methods for shape and property collaborative assembly of composite and metal components, and to offer guidance for process strategy formulation of collaborative control.

针对航空航天领域对型号高装配精度和长寿命服役的迫切需求，以及复合材料（简称复材）应用范围的不断扩大，必须严格控制复材与金属构件装配中的变形和应力。然而，现有研究多以保证结构几何精度为主，较少考虑装配后的物理性能；且复材构件成型精度低，在装配中易产生二次损伤。鉴于此，项目围绕复材与金属构件装配中几何精度与物理性能协同保障这一核心问题，进行复材、金属和工装制造误差场精确建模，构建耦合多源制造误差的数字化装配模型；发展高性能装配数值预测方法，开展多工艺-几何约束下的变形预测、应力分析及形性协同控制研究。揭示多制造误差多装配载荷耦合条件下的变形传递与应力演变及其相互作用机理，掌握影响装配性能的主要因素及其影响规律；探索力-位混合约束下的变形-应力权衡机制，结合智能算法进行优化求解，并开展典型结构件实验验证。旨在为复材与金属构件的形性协同装配提供理论支撑和技术基础，为协同控制的工艺策略制定提供指导。

新一代飞机结构为满足高比强度、轻量化以及飞行性能等方面的要求，大量使用以碳纤维增强树脂基复合材料（以下简称复材）为代表的先进材料。然而，复材构件成型精度较低，存在不同程度的回弹与翘曲变形，与金属结合面易形成非均匀分布的装配间隙，在装配中易产生较大的局部装配应力，装配后结构几何精度和物理性能难以保证。项目针对复材与金属构件装配中变形预测及形性协同控制这一核心问题，开展了复合材料构件制造误差建模方法研究、复合材料构件装配变形预测及影响因素分析和基于装配顺序优化的复合材料构件装配变形控制研究。以复合材料构件实测数据为基础，对实测点云数据进行滤波和ICP配准获得制造误差场；采用离散余弦变换开展制造误差模式分解与识别建模方法研究，并进行重建精度评价；结果表明，考虑制造误差的分析模型比理论模型在装配变形预测方面更接近实验结果。以构件装配平均变形为评价目标，以构件间装配水平间隙、拧紧力与钉杆-孔配合精度为影响因素，开展正交有限元分析，分析表明，相比于连接工艺参数，水平间隙对变形的影响更大，且当水平间隙大于0.2mm时，应当进行填隙处理。以复材构件装配变形最小为优化目标，基于遗传算法开展螺栓连接顺序优化，开发了MATLAB和ABAQUS软件联合仿真流程，完成了典型结构装配工艺验证。项目提出了考虑制造误差的复材与金属构件装配性能分析方法，为复材/金属构件或复材/复材构件的高精度、低应力装配提供了技术支撑。