Transactions of Materials and Heat Treatment

Title：Crack analysis and structural optimization on incremental press bending process for non-uniform thickness plate of 2195 aluminum-lithium alloy

Authors： Chen Lele1 Hu Deyou1 Nan Kangbin2 Han Yunqi2 Lou Shumei2 Chu Guannan3

Unit： 1. Tianjin Aerospace Long March Vehicle Manufacturing Co. Ltd. Tianjin 300462 China 2.Department of Intelligent Equipment Shandong University of Science and Technology Tai′an 271019 China 3.School of Materials Science and Engineering Harbin Institute of Technology (Weihai)

KeyWords： 2195 aluminum-lithium alloy non-uniform thickness plate incremental press bending crack stress concentration

ClassificationCode：TG386

year,vol(issue):pagenumber：2025,50(7):67-73

Abstract：

For the cracks occurred at the intersection of bosses, holes and ribs in the incremental press bending process for non-uniform thickness plate of 2195 aluminum-lithium alloy, the finite element analysis was performed by ABAQUS, and it was determined that these cracks were generated by the shear deformation caused by shear force and the stress state at the fracture location was triaxial tensile stress, which accelerated the fracture of the plate. Then, based on the simulation results and production conditions, it was proposed to alleviate the uneven stress distribution and the shear plastic deformation caused by excessive thickness differences through a gradual thickness transition in skin at the blank boss interface, which enhanced the structural strength and stability of this area and reduced the fracture risk caused by stress concentration. Furthermore, the optimized scheme was subjected to finite element analysis by ABAQUS. The results show that the distributions of Mises equivalent stress, normal stress and shear stress after optimization are more uniform. The stress at the original crack location is significantly reduced, the crack resistance of the material is effectively improved, and the products meeting the requirements are processed.

Funds：

作者简介：陈乐乐（1986-），女，硕士，工程师 E-mail：chenlele86@126.com 通信作者：娄淑梅（1979-），女，博士，教授 E-mail：msl7119@163.com

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