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Zemin Fu Jianhua Mo Fei Han Pan Gong 《The International Journal of Advanced Manufacturing Technology》2013,64(9-12):1239-1248
There exists some error between the manufactured part shape and the designed target shape due to springback of this part after forming. To reduce the error, an iterative algorithm of closed-loop control for correcting tool path of the single-point incremental forming, based on Fast Fourier and wavelet transforms, has been developed. Moreover, the data of the springback shapes, after unloading, of the sheet metal parts formed with the trial and corrected tool paths, used for iterative correction of tool path in the algorithm, are obtained with finite element model (FEM) simulation. Then, a truncated pyramid-shaped workpiece, whose average errors are +0.183/?0.175 mm, was made with the corrected tool path after three iterations solved by the above algorithm and simulation data. The results show that the tool path correction algorithm with Fourier and wavelet transforms is reasonable and the means with FEM simulation are effective. It can be taken as a new approach for single-point incremental forming of sheet metal and tool path design. 相似文献
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Zemin Fu Jianhua Mo Wenxian Zhang 《The International Journal of Advanced Manufacturing Technology》2009,45(5-6):448-458
A mathematical model of springback radius was developed with dimensional analysis and orthogonal test. With this model, the punch radius could be solved for forming high-precision semiellipse-shaped workpieces. With the punch radius and other geometrical parameters of a tool, a 2D ABAQUS finite-element model (FEM) was established. Then, the forming process of sheet metal multiple-step incremental air bending was simulated with the FEM. The result showed that average errors of the simulated workpiece were +0.68/?0.65 mm, and provided the process data consisting of sheet feed rate, punch displacement and springback angle in each step. A semiellipse-shaped workpiece, whose average errors are +0.68/?0.69 mm, was made with the simulation data. These results indicate that the punch design method is feasible with the mathematical model, and the means of FEM simulation is effective. It can be taken as a new approach for sheet metal multiple-step incremental air-bending forming and tool design. 相似文献
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Zemin Fu Pan Gong 《The International Journal of Advanced Manufacturing Technology》2014,71(1-4):357-364
To solve the springback problem for sheet metal forming, feedback control idea in automatic control theory is introduced to incremental air-bending forming process. The advanced control techniques are used to solve precision forming for workpiece of sheet metal. However, stability, accuracy, and rapidity of closed-loop control can directly affect system normal operation. Aiming to analyze the effect of stability on the quality of the formed workpiece, a closed-loop control system model for incremental air-bending forming is established. The transfer function and characteristic equation of the closed-loop system are solved through theory deduction and minor incremental linearization method. Both simulations with Matlab/Simulink and root locus results show that, as the overall gain is equal to one, the shape of formed part could converge to the target shape at the fastest rate. Finally, a semiellipse-shape workpiece is manufactured with the corrected mold obtained by the closed-loop forming method. The experimental results show that the closed-loop forming way is feasible and the means of correcting the mold parameters by iterative compensation of the stable closed-loop control system is effective. It can be taken as a new approach for sheet metal incremental air-bending forming and mold design. 相似文献
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Zemin Fu Wei Chen Xiuli Tian Bingkun Hu 《The International Journal of Advanced Manufacturing Technology》2014,72(5-8):561-570
Based on Hill’s yielding criterion and plane strain condition, the explicit expressions of elastoplastic constitutive model are derived in this paper which takes into account the effects of transverse stress, neutral surface shifting, and sheet thickness thinning on the sheet springback of air-bending. Then, this model is embedded into ABAQUS software platform by means of programming. Finally, 3D ABAQUS finite-element models (FEM), used to form the semiellipse-shaped workpiece with super length and large opening of sheet metal, are established, and the multiple-step incremental air-bending forming and springback processes are simulated. The simulation and experiment results show that the data predicted with the new constructed constitutive model under the plane strain condition are in much better agreement with experimental data than those predicted with the constitutive model built-in ABAQUS. It can be taken as a valuable mathematical tool used for multiple-step incremental air-bending forming simulation of large area sheet metal. 相似文献
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主要研究了金属板材数控单点渐进成形过程中的回弹问题 ,分析了影响板材渐进成形回弹的主要因素和变化规律 ,提出了一种通过增大成形角度控制回弹的方法。 相似文献
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Iterative methods based on finite element simulation are effective approaches to design mold shape to compensate springback in sheet metal forming. However, convergence rate of iterative methods is difficult to improve greatly. To increase the springback compensate speed of designing age forming mold, process of calculating springback for a certain mold with finite element method is analyzed. Springback compensation is abstracted as finding a solution for a set of nonlinear functions and a springback compensation algorithm is presented on the basis of quasi Newton method. The accuracy of algorithm is verified by developing an ABAQUS secondary development program with MATLAB. Three rectangular integrated panels of dimensions 710 mmx750 mm integrated panels with intersected ribs of 10 mm are selected to perform case studies. The algorithm is used to compute mold contours for the panels with cylinder, sphere and saddle contours respectively and it takes 57%, 22% and 33% iterations as compared to that of displacement adjustment (DA) method. At the end of iterations, maximum deviations on the three panels are 0.618 4 mm, 0.624 1 mm and 0.342 0 mm that are smaller than the deviations determined by DA method (0.740 8 mm, 0.740 8 mm and 0.713 7 mm respectively). In following experimental verification, mold contour for another integrated panel with 400 ram~380 mm size is designed by the algorithm. Then the panel is age formed in an autoclave and measured by a three dimensional digital measurement devise. Deviation between measuring results and the panel's design contour is less than 1 mm. Finally, the iterations with different mesh sizes (40 mm, 35 mm, 30 mm, 25 mm, 20 mm) in finite element models are compared and found no considerable difference. Another possible compensation method, Broyden-Fletcher-Shanmo method, is also presented based on the solving nonlinear fimctions idea. The Broyden-Fletcher-Shanmo method is employed to compute mold contour for the second panel. It only takes 50% iterations compared to that of DA. The proposed method can serve a faster mold contour compensation method for sheet metal forming. 相似文献
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Haibo Lu Michael Kearney Sheng Liu William J.T. Daniel Paul A. Meehan 《The International Journal of Advanced Manufacturing Technology》2017,91(1-4):91-106
Incremental sheet forming (ISF) is an emerging forming technology that promises high flexibility and formability. These properties make it suited for small-scale and customised production. However, the poor geometric accuracy of ISF limits the wide application of this flexible forming technology. This paper presents a two-directional toolpath correction approach to enhance ISF forming accuracy using a model predictive control (MPC) algorithm. A toolpath optimisation method for vertical toolpath correction has been validated in our previous work (Lu et al., Int J Adv Manuf Technol 72:1–14, 2015), and it helps to reduce errors in the base of the test shapes to a suitable level while its major limitation is that horizontal geometric errors are relatively large. This paper extends our previous work (Lu et al., Int J Adv Manuf Technol 72:1–14, 2015) by augmenting the vertical control module with a new control module for horizontal toolpath correction. The proposed control algorithm was experimentally validated in single-point incremental sheet forming (SPIF) using two forming case studies. In the first case study (a truncated pyramid), two control approaches with different assumptions for the horizontal springback distribution along the horizontal cross-sectional profile were tested and compared. Then, the developed MPC control algorithm was applied to form a more complex asymmetric shape. The results show that the developed strategy can reduce the forming errors in the wall and base of the formed shape compared to the existing works. The ISF process with MPC control leads to significant accuracy improvement in comparison with the typical ISF process that is without toolpath control. 相似文献
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利用积分滤波器对加速度信号进行二次积分,从而获得物体的运动位移信息;为提高系统的稳定性和抗噪性,在积分前分别采用减平均值法和小波变换对加速度信号进行去直流量及去噪处理;通过仿真信号验证算法的正确性,降低了实验成本;最后利用采用XW-IMU5250惯性测量单元实测一个物体的运动,得到了物体精确的运动轨迹。 相似文献
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基于非线性有限元的钣金件成形极限研究 总被引:4,自引:0,他引:4
用非线性有限元软件包 SHEET- FORMING研究橡皮成形工艺的模具圆角半径和板料厚度对钣金件凹凸翻边成形极限的影响 ,建立了用于预测橡皮成形工艺成败和分析其原因的极限翻边高度 h、模具圆角半径 r凹 / r凸 、板料厚度 t的曲面关系 ,用非线性有限元法有效地取代了坐标网应变法。文中主要论述 ,以圆框为对象 (L Y12 M)和用试验得到的成形极限曲线作判据 ,选取合适参数范围作正交设计 ,用动力显式算法对凹翻边破裂数值模拟并与生产型试验结果进行对比基本吻合。 相似文献
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稳态谐波信号的分析常采用快速傅里叶变换(FFT),但对于暂态信号的误差较大。离散小波变换(DWT)特别适合于非稳态信号的分析,但对于稳态谐波的分析效果没有FFT好。结合柴油发电机电网的特点,提出了基于FFT和DWT的联合分析方法。首先通过DWT将柴油发电机电网谐波信号分解为低频稳态部分和高频暂态部分,再采用FFT和db4小波对两部分信号分量依次进行分析。利用Matlab软件仿真,分析算法获得了较好的预期效果,说明联合分析策略在柴油发电机电网谐波分析中具有一定的可行性和实用性。 相似文献
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Determining the optimum variable blank-holder forces using adaptive response surface methodology (ARSM) 总被引:2,自引:0,他引:2
S. Chengzhi C. Guanlong L. Zhongqin 《The International Journal of Advanced Manufacturing Technology》2005,26(1-2):23-29
Wrinkling and fracture are main defects in sheet-metal forming. They can be reduced or eliminated by manipulating a suitable blank-holder force (BHF). But it is difficult to attain the optimum BHF during sheet-metal forming. In this article, a new optimization algorithm integrating the finite element method (FEM) and adaptive response surface methodology $(r)ARSM$(c) is presented to determinate the optimum BHF. To assure convergence, the trust region modes management strategies are used to adjust the move limit of design spaces. Finally, the optimum results of rectangular box deep drawing are given. Experiments are performed to verify the optimal result. 相似文献
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详述了Fourier变换与小波变换的本质区别,分析了Fourier变换和短时Fourier变换应用于故障检测的不足;介绍了小波变换及其应用于故障检测的优点;指出了小波变换应用于故障检测的理论和方法。 相似文献
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