纤维金属层板(FMLs)兼具金属与复合材料的性能优势，在航空、航天等领域具有广阔应用前景，然而其完全固化后成形性能差，难以一次成形复杂曲面构件，制约了其整体化设计与制造潜力的发挥。本工作提出一种基于固体颗粒介质(SGM)的FMLs半固态成形-固化一体化工艺，旨在实现复杂形状构件的高质量、低损伤成形。通过构建涵盖颗粒介质、铝合金层、玻璃纤维预浸料及层间界面的精细化有限元模型，系统揭示了SGM柔性成形与半固化材料状态的协同增效机制，并深入分析了压边间隙、试件初始尺寸等关键工艺参数对拉深类零件成形质量的影响规律。结果表明，相较于传统刚性模具成形，SGM柔性成形工艺可使拉深高度提升约22%，并有效缓解凹模圆角区的应力集中现象；同时，半固化层合板凭借其树脂的黏性流动与界面滑移补偿效应，成形极限较完全固化状态提高约16.8%。经颗粒介质成形+保压升温固化过程后，所得FMLs构件的层间结合紧密，界面完整清晰，满足质量要求。在制造复杂形状FMLs构件时，采用本工作提出的固体颗粒介质一体化成形工艺，可有效提高FMLs成形极限，保障构件高质量成形，还可显著简化生产流程。
Fiber metal laminates
(FMLs) combine the performance advantages of metallic and composite materials;
consequently, they have broad application potential in aerospace and aviation.
However, their limited formability after complete curing hinders the one-step
fabrication of components with complex curved geometries, thereby restricting their
potential for integrated design and manufacturing. Therefore, this study
proposes an integrated forming and curing process for semicured FMLs using a
solid granule medium (SGM), with the aim of achieving high-quality forming
while minimizing material damage. A refined finite element model incorporating
the SGM, aluminum alloy layer, glass-fiber prepreg, and interlayer interface
was developed to investigate the coupled effects of flexible SGM forming and
the semicured material state. The effects of key process parameters, including
the blank-holder gap and specimen size, on the forming quality of deep-drawn
components were systematically analyzed. Compared with the conventional rigid
mold forming process, SGM forming increased the deep-drawing height by
approximately 22% and effectively reduced stress concentration in the die-fillet
region. Owing to the viscous resin flow and compensating interlayer slip, the
forming limit of the semicured laminate was approximately 16.8% higher than that
of the fully cured laminate. After SGM forming, the components were cured under
pressure during a controlled heating process. The cured FMLs exhibited strong interlayer bonding and clear,
intact interfaces, with no interfacial defects observed. These results demonstrate that the proposed SGM forming
and curing process can improve the formability of FMLs, reduce forming-induced
damage, and simplify the production of complex-shaped components.
