Wing ribbed wallboard of large aircraft and manufacturing process of wing ribbed wallboard

Abstract

The invention provides a large aircraft wing ribbed wallboard, which is characterized in that before the manufacturing process of the large aircraft wing ribbed wallboard is started, finite element joint analogue simulation is firstly carried out on stretch forming and shot peening strengthening processes, so that an optimal stretching force loading curve matched with a material, a mold avoidance groove specification and optimal low-energy shot peening parameters can be obtained; in the manufacturing process, a single profile blank is prepared through an integrated extrusion and quenching combined technology, and synchronous improvement of the overall rigidity and the material utilization rate is facilitated; in the stretching process, residual tensile stress is introduced into the core part of the wallboard through pre-stretching and can form a synergistic strengthening effect with surface residual compressive stress generated by subsequent shot blasting, so that the fatigue life of the wallboard is greatly prolonged; and shot blasting adopts a low-energy mode, so that various defects caused by traditional high-energy spraying can be effectively avoided while the surface appearance and the pressure stress precision are ensured. The optimization process gets rid of the dependence on complex clamping equipment in the prior art, and correspondingly eliminates the deformation risk caused by clamping stress.

Description

Technical Field

[0001] This invention belongs to the field of large aircraft manufacturing technology, specifically relating to stiffened wing panels for large aircraft and their manufacturing process. Background Technology

[0002] As a crucial component of aircraft structures, wing panels were initially assembled using skin and longitudinal and transverse reinforcing parts through riveting, gluing, or spot welding. However, the rigidity, strength, and sealing performance of these finished products no longer meet the requirements of advanced aircraft. Therefore, they have gradually been replaced by integral panels manufactured through a series of processes including blanking, machining, and forming. Currently, in the manufacturing of some large and relatively complex integral wing panels, issues such as low machining accuracy and yield, cumbersome processes, and long production cycles remain unresolved in several stages, including stretching and shot peening. For example, existing shot peening technologies such as Chinese patents CN115635004A and CN110666701A heavily rely on specialized pre-clamping fixtures and extremely complex installation and shot peening parameter adjustment processes. While patents CN111716255A, CN116967371A, and CN114799756A have achieved some degree of accuracy improvement through adjustments to certain process steps, they have not significantly simplified the overall process or shortened the production cycle. More importantly, existing technologies generally require high shot peening energy to achieve material deformation, which can easily lead to defects such as pits and roughness deterioration on the surface of the panel. At the same time, the mechanical properties of the core material are difficult to be effectively strengthened through a single shot peening process, which further leads to the high overall manufacturing cost of the panel. Summary of the Invention

[0003] In view of this, and to address the technical problems existing in this field, the present invention provides a manufacturing process for stiffened panels on large aircraft wings, specifically including the following steps:

[0004] S1. Conduct mechanical property tests on the metal materials used to prepare the wall panels. Use a tensile testing machine to conduct single tensile tests on the metal profile samples to obtain mechanical property data of the material at room temperature, including yield strength, tensile strength, elongation, etc. At the same time, determine the initial hardness state of the material through hardness testing.

[0005] S2. Based on the relevant data of various metal material properties obtained in step S1, a simulation model of the tensile forming and shot peening process of the stiffened panel is established using finite element software. First, the tensile forming process is simulated, and the stress-strain distribution characteristic cloud map of the entire panel and each key part is plotted. Then, the shot peening process is simulated, the formation process and distribution law of the pressure layer on the material surface are extracted and analyzed, and the strengthening effect corresponding to the shot peening parameters composed of different shot materials, shot diameters, blasting pressures and blasting time parameters is predicted.

[0006] S3. Based on the finite element simulation results of step S2, set and optimize the working parameters of the tensile machine for the stiffened panel: including the tensile force loading curve, the size of the clearance groove, etc., and verify and set the low-energy shot peening parameters in conjunction with the Almen test piece.

[0007] S4. Based on the clearance groove size parameters set in step S3, make the corresponding ribbed wall panel mold so that clearance grooves matching the shape of the vertical ribs of the target wall panel are formed on the mold surface, and perform precision detection to determine whether the surface curvature and other parameters meet the design requirements.

[0008] S5. The metal sheet blanks for processing ribbed wall panels are prepared by using an integrated extrusion and quenching process. After completion, the blanks are transferred to a large-tonnage stretching machine.

[0009] S6. Start the stretching machine to stretch the billet and continuously monitor the tensile force and strain data with the assistance of sensors. During the forming process, an initial pre-tension force is first applied to make the billet elastically deform and form a uniform tensile stress in its core. Then, the tension is gradually increased to make the billet conform to the mold surface under the action of the avoidance groove, and the coordinated deformation of the vertical rib and the wall panel body will finally achieve shape strengthening. After completion, a uniform tensile stress will be formed in the core of the wall panel. Combined with low-energy shot peening, a compressive stress layer is introduced on the surface, which significantly reduces the overall springback and the surface roughness is lower. The quality of the finished product will be much better than that of traditional processes.

[0010] S7. With the assistance of measuring equipment, the stiffened wall panel after stretching and forming is subjected to CNC machining including milling, drilling, and grooving to ensure that its dimensional accuracy meets the design and assembly requirements.

[0011] S8. Based on the set low-energy shot peening parameters, the ribbed wall panel is subjected to shot peening strengthening treatment. After the depth of the compressive stress layer and surface roughness of the wall panel are detected, the processing process ends.

[0012] S9. Perform comprehensive quality inspection on the completed ribbed wall panels, including dimensional accuracy measurement, mechanical property testing, and surface quality assessment. Compare the test results with the design standards to obtain the final qualified finished product.

[0013] Furthermore, aluminum alloy is specifically selected as the metal material for manufacturing the stiffened panels of aircraft wings.

[0014] Accordingly, the present invention also provides a large aircraft wing stiffened panel, which is manufactured using the large aircraft wing stiffened panel manufacturing process proposed in the present invention.

[0015] The large aircraft wing stiffened panel provided by the present invention undergoes a finite element joint simulation of the stretching forming and shot peening process before manufacturing begins. This simulation determines the optimal tensile force loading curve, mold avoidance groove specifications, and optimal low-energy shot peening parameters that match the material. During manufacturing, a single profile blank is prepared using an integrated extrusion combined with quenching process, replacing the multi-part riveted plate form in traditional processes, thus simultaneously improving overall rigidity and material utilization. During the stretching process, residual tensile stress is introduced into the core of the panel through pre-stretching, which can form a synergistic strengthening effect with the surface residual compressive stress generated by subsequent shot peening, greatly extending the fatigue life of the panel. Under the auxiliary extrusion of the mold avoidance groove, the panel can also achieve more uniform deformation. The shot peening uses a low-energy method, which can effectively avoid various defects caused by traditional high-energy peening while ensuring the surface shape and compressive stress accuracy. The optimized process of the present invention can eliminate the dependence on complex clamping equipment in existing technologies, and correspondingly eliminate the deformation risk caused by clamping stress. Attached Figure Description

[0016] Figure 1 The present invention provides optional structural forms for the integral large aircraft wing stiffened panel. Detailed Implementation

[0017] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] The manufacturing process for stiffened panels on large aircraft wings provided by this invention specifically includes the following steps:

[0019] S1. Conduct mechanical property tests on the metal materials used to prepare the wall panels. Use a tensile testing machine to conduct single tensile tests on the metal profile samples to obtain mechanical property data of the material at room temperature, including yield strength, tensile strength, elongation, etc. At the same time, determine the initial hardness state of the material through hardness testing.

[0020] S2. Based on the relevant data of various metal material properties obtained in step S1, a simulation model of the tensile forming and shot peening process of the stiffened panel is established using finite element software. First, the tensile forming process is simulated, and the stress-strain distribution characteristic cloud map of the entire panel and each key part is plotted. Then, the shot peening process is simulated, the formation process and distribution law of the pressure layer on the material surface are extracted and analyzed, and the strengthening effect corresponding to the shot peening parameters composed of different shot materials, shot diameters, blasting pressures and blasting time parameters is predicted.

[0021] S3. Based on the finite element simulation results of step S2, set and optimize the working parameters of the tensile machine for the stiffened panel: including the tensile force loading curve, the size of the clearance groove, etc., and verify and set the low-energy shot peening parameters in conjunction with the Almen test piece.

[0022] S4. Based on the clearance groove size parameters set in step S3, make the corresponding ribbed wall panel mold so that clearance grooves matching the shape of the vertical ribs of the target wall panel are formed on the mold surface, and perform precision detection to determine whether the surface curvature and other parameters meet the design requirements.

[0023] S5. The metal sheet blanks for processing ribbed wall panels are prepared by using an integrated extrusion and quenching process. After completion, the blanks are transferred to a large-tonnage stretching machine.

[0024] S6. Start the stretching machine to stretch the blank and continuously monitor the tensile force and strain data with the assistance of sensors. During the forming process, first apply an initial pre-tension force to make the blank elastically deform and form a uniform tensile stress in its core. Then gradually increase the tension force to make the blank conform to the mold surface under the action of avoiding the groove, and make the ribs and the wall panel body deform together to finally achieve shape strengthening.

[0025] S7. With the assistance of measuring equipment, the stiffened wall panel after stretching and forming is subjected to CNC machining including milling, drilling, and grooving to ensure that its dimensional accuracy meets the design and assembly requirements.

[0026] S8. Based on the set low-energy shot peening parameters, the ribbed wall panel is subjected to shot peening strengthening treatment. After the depth of the compressive stress layer and surface roughness of the wall panel are detected, the processing process ends.

[0027] S9. Perform comprehensive quality inspection on the completed ribbed wall panels, including dimensional accuracy measurement, mechanical property testing, and surface quality assessment. Compare the test results with the design standards to obtain the final qualified finished product.

[0028] Aluminum alloy is specifically selected as the metal material for manufacturing the stiffened panels of aircraft wings.

[0029] Accordingly, the present invention also provides a large aircraft wing stiffened panel, which is manufactured using the large aircraft wing stiffened panel manufacturing process proposed in the present invention.

[0030] It should be understood that the sequence number of each step in the embodiments of the present invention does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0031] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for stiffened panels on a large aircraft wing, specifically including the following steps: S1. Conduct mechanical property tests on the metal materials used to prepare the wall panels. Use a tensile testing machine to conduct single tensile tests on the metal profile samples to obtain mechanical property data of the material at room temperature, including yield strength, tensile strength and elongation. At the same time, determine the initial hardness state of the material through hardness testing. S2. Based on the relevant data of various metal material properties obtained in step S1, a simulation model of the tensile forming and shot peening process of the stiffened panel is established using finite element software. First, the tensile forming process is simulated, and the stress-strain distribution characteristic cloud map of the entire panel and each key part is plotted. Then, the shot peening process is simulated, the formation process and distribution law of the pressure layer on the material surface are extracted and analyzed, and the strengthening effect corresponding to the shot peening parameters composed of different shot materials, shot diameters, blasting pressures and blasting time parameters is predicted. S3. Based on the finite element simulation results of step S2, set and optimize the working parameters of the tensile machine for the stiffened panel: including the tensile force loading curve, the clearance groove size parameters, and the low-energy shot peening parameters verified and set in conjunction with the Almen test piece. S4. Based on the clearance groove size parameters set in step S3, make the corresponding ribbed wall panel mold so that clearance grooves matching the shape of the vertical ribs of the target wall panel are formed on the mold surface, and perform accuracy detection to determine whether the surface curvature parameters meet the design requirements. S5. The metal sheet blanks for processing ribbed wall panels are prepared by using an integrated extrusion and quenching process. After completion, the blanks are transferred to a large-tonnage stretching machine. S6. Start the stretching machine to stretch the billet and continuously monitor the tensile force and strain data with the assistance of sensors; During the forming process, an initial pre-tension is first applied to cause the blank to undergo elastic deformation and form a uniform tensile stress in its core. Then, the tension is gradually increased to make the blank conform to the mold surface under the action of the avoidance groove, and the coordinated deformation of the vertical rib and the wall panel body finally achieves shaping and strengthening. S7. With the assistance of measuring equipment, perform necessary CNC machining on the stretched and formed stiffened wall panel, including milling, drilling and grooving, so that its dimensional accuracy meets the design and assembly requirements. S8. Based on the set low-energy shot peening parameters, the ribbed wall panel is subjected to shot peening strengthening treatment, and the depth of the compressive stress layer and surface roughness index of the wall panel are detected. The processing process ends after that. S9. Perform comprehensive quality inspection on the completed ribbed wall panels, including dimensional accuracy measurement, mechanical property testing, and surface quality assessment. Compare the test results with the design standards to obtain the final qualified finished product.

2. The manufacturing method of the stiffened panel for a large aircraft wing as described in claim 1, characterized in that: Aluminum alloy is specifically selected as the metal material for manufacturing the stiffened panels of aircraft wings.

3. A stiffened panel for a large aircraft wing, characterized in that: It is manufactured using the manufacturing process for stiffened panels of large aircraft wings as described in claim 1 or 2.

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