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

本研究所用的复合材料板称为超级混杂板，它是由许多薄的铝合金板和单向CFRP或KFRP或CFRP/KFRP混杂层组成。这种板在室温下在一定的极限条件下可以塑性成形。由于材料形成无缺陷的范围相对较窄，因此在此形成过程中存在一些问题。超级混杂板是一种非常柔韧的材料，在不固化的情况下具有很宽的塑性变形范围。此外，塑性变形的铝层本身将能够构成用于FRP层的模具。作者将这种独特的性能称为可预成形性，并据此提出了一种新的V形成形工艺，即先将5086铝合金薄板与FRP层合而成的叠层材料在室温下预成形，然后在适当的温度和压力下热压固化。通过使用该方法，可以获得具有尖锐的V形弯曲的精细制品，其半径为2.5mm，几乎等于板厚度。另一方面，该方法产生了成形制品厚度的波动。为了解决该问题，使用简单的装置在高压釜中固化预成型制品以消除制品的回弹。因此，开发了一种新的V形成形工艺，以获得具有回弹和精确90度弯曲角的制品。利用超级混杂材料的预成形性、真空袋和高压釜PVA工艺确定了新的成形工艺，并将PVA工艺应用于鞍形曲面和球面的成形试验，结果表明，与传统的成形方法相比，新方法对曲面成形的改善不大。

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.