A New V-shape Forming Process for Super Hybrid Material Using Pre-formability of It

本文所用的复合材料板被称为超级混杂板，它是由许多铝合金薄板与单向CFRP或KFRP或CFRP/KFRP混杂铺层组成的。在一定的极限条件下，这种板材可以在室温下塑性成形。由于该材料无缺陷成形的范围较窄，在该成形过程中存在一些问题。超级混杂板材非常灵活，如果不固化，塑性变形范围很大。此外，塑性变形的铝层本身将能够组成FRP层的模具。作者将这一独特的性质称为预成形性，并在此基础上提出了一种新的V形成形工艺。首先将由5086铝合金板材和玻璃钢铺层组成的叠层材料Al在室温下预成型，然后在适当的温度和压力下进行热压固化。通过使用这种方法，可以获得半径为2.5 mm的尖锐V形弯曲的精细物品，其半径几乎等于板的厚度。另一方面，该方法产生了成形制品的厚度波动。为了解决这一问题，使用一个简单的装置来消除预制件的回弹，将预制件在高压罐中固化。因此，开发了一种新的V形成形工艺，以获得具有精确90度弯曲角度的回弹制品。提出了利用超混杂材料的预成形性、真空袋和高压釜式PVA工艺进行成形的新工艺，并应用该工艺进行了马鞍面和球面等涉水曲面成形试验，结果表明，与传统工艺相比，该工艺对涉水曲面的成形几乎没有改善。

The composite material plate used in this study is called super hybrid plate, which is built up from many thin aluminum alloy sheets and unidirectional CFRP or KFRP or CFRP/KFRP hybrid layrs. This plate can be formed plastically at room temperature under certain limiting condtions. Because of the range that the material is formed without defects is relatively narrow, there are some problems in this forming process. Super hybrid plate is very flexible and has a wide plastic deformation range if it is not cured. Moreover, plastically deformed aluminum layrs themselves will be able to compose a mold for FRP layrs. The author called this unique property pre-formability and proposed a new V-shape forming proess based on it. First of al, a stacked material, consisted of 5086 aluminum alloy sheets and FRP layrs, was pre-formed at room temperature, then cured under the appropriate temperature and pressure by using hot-press. By using this method, it became possible to get fine articles having sharp V-bent with radius 2.5mm that is nearly equal to the plate thickness. On the other hand, this method produced a fluctuation of thickness of the formed article. To solve the Problem the pre-formed articles were cured in the autoclave using a simple device to cancel the spring back of the articles. As a result, a new V-shape forming process to get articles with to spring back and with exact 90 degrees bending angle was developed. The author defined the new forming process using pre-formability of the super hybrid material, vacuum bag and autoclave PVA process.Tests of dabble-curved surface forming such as saddleback and spherical surface forming were performed as an application of PVA process.The results showed that the new method could hardly improve the dabble-curved surface forming compared with conventional method.