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

本研究中使用的复合材料板称为超级混杂板，它是由许多薄铝合金板和单向CFRP或KFRP或CFRP/KFRP混杂层组成的。在一定的极限条件下，这种板可以在室温下形成塑性。由于材料成形无缺陷的范围比较窄，因此这种成形工艺存在一些问题。超级混合板非常灵活，如果不固化，塑性变形范围很广。此外，塑性变形的铝层本身将能够构成玻璃钢层的模具。作者将这种独特的特性称为预成形性，并在此基础上提出了一种新的v形成形工艺。首先，将5086铝合金板材与玻璃钢层在室温下进行预成型，然后在适当的温度和压力下进行热压固化。通过这种方法，可以得到半径为2.5mm，几乎等于板厚的尖锐v形弯曲的精细制品。另一方面，这种方法产生了成形件厚度的波动。为了解决这一问题，采用了一种简单的装置来消除预成形件的回弹，并在高压灭菌器中对预成型件进行了固化。为此，提出了一种新的v形成形工艺，可使零件具有精确的90度弯曲角和回弹。提出了利用超杂化材料的预成形性、真空袋和热压罐PVA工艺进行成形的新工艺。作为PVA工艺的应用，进行了马鞍形和球面等浅层曲面成形试验。结果表明，与传统方法相比，新方法几乎不能改善浅面曲面的成形。

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.