自由曲面工件多点连续成形方法

为了实现自由曲面工件的高效率、低成本制造，分析与比较常用的柔性成形方法；从成形过程的连续性考虑，将柔性成形分为分段成形与连续成形；从变形区大小考虑，又划分为点成形、面成形与线成形等不同类型。比较不同成形方式的优点与缺点，指出自由曲面工件的高质量、高效率成形是亟待解决的技术难题。提出基于连续线成形方法的自由曲面工件高效、柔性成形思路；并提出采用多点调整式柔性辊的多点连续成形技术方案；探讨多点连续成形技术的基本原理、关键技术及主要特点。运用具有多个控制点的挠性轴设计出可弯曲、可调整的柔性辊，开发出多点卷板成形试验装置。多种三维曲面板类件的连续成形试验结果表明，多点连续成形技术能够解决自由曲面工件的高效加工难题。

METHOD OF MULTIPOINT CONTINUOUS FORMING FOR THE FREEFORM SURFACE PARTS

In order to realize the freeform surface parts formed with the efficiency and economy, the ordinary methods of flexible forming are analyzed. Based on forming process continuity, flexible forming can be classified sectional forming and continuous forming, and according to deformed area it can be divided into point, facet and line forming. Through comparing different forming methods, a critical problem to achieve high quality and high efficiency forming the freeform surface parts is proposed. Based on the above analysis, a novel idea of forming freeform surface parts by the continuous line forming that has characteristic of efficiency and flexibility is proposed. And the technology project of forming the freeform surface parts by adopting the multipoint continuous forming technology using multipoint adjustable rollers is developed. Moreover, basic principle, key technologies and characteristics of multipoint continuous forming are discussed. Subsequently, the novel flexible roller forming means which has a flexible shaft with many controllable points is applied and the experimental device concerned with this technology using the multipoint adjustable rollers is developed. The results of the continuous forming experiments on forming kinds of 3D surface parts makes it clear that the above technology is suitable to solve the critical problem of the freeform surface parts forming with high efficiency.