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《CIRP Annals》2019,68(1):317-320
Limited geometric accuracy in incremental sheet forming is a major obstacle for its wide adoption in industry. This paper develops a generic methodology, suitable for arbitrary part geometries and various ISF processes, for addressing one of the main causes of geometric inaccuracy, i.e., in-process springback. The methodology consists of three main elements: determination of key control points to treat geometric complexity, simplified simulation models to predict springback offline, and in-situ toolpath modification during forming. It is shown experimentally that the method provides an efficient and robust solution for various geometries with negligible setup cost. 相似文献
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《Journal of Materials Processing Technology》2014,214(8):1673-1685
In this paper, an enhanced numerical method for forming tool design optimisation in three-dimensional (3D) sheet metal forming applications is presented. The applied procedure enables a determination of appropriate forming tool geometry so that the manufacture of a sheet metal product inside specified tolerances would be ensured. In addition to the springback that occurs in the formed part after removal of the forming tools, the impact of the thinning of the sheet metal during the forming process is considered in the method, and both effects are correspondingly compensated for an iterative procedure. Computational efficiency in the E-DA-3D method is achieved mainly because the improved accuracy of the communicated data established corresponding interrelations between the discretised topologies used in the definition of the prescribed product geometry, the current tool geometry, and on this basis actually computed product geometry which is achieved by means of additional point topology mappings. The potential and effectiveness of the method is demonstrated by considering two cases of the forming tool design optimisation that are also experimentally validated. 相似文献
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With the rising interest in lightweight construction, the usage of high and ultra-high strength steels has increased remarkably
during the last years. Unfortunately, these steel grades show more springback than mild steels do, which leads in consequence
to lower dimensional accuracy. To improve the bended part’s geometry considerable trial-and-error work is necessary since
the influence of different bending-parameters (e.g. the bending radius, sheet thickness, yield strength, Young’s modulus,
the material’s strain hardening coefficient, …) on the amount of springback is still unknown. The aim of the paper at hand
is therefore the investigation of springback for different parameter combinations. Furthermore, an online calibration system
for occurring springback during roll forming is presented to compensate springback independent of material or process parameters. 相似文献
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利用模具型面补偿的方法控制回弹,是模具生产中常用的控制回弹的方法。以炉具前面板为例,采用模具型面补偿的方法对其回弹进行了控制。利用此种方法设计出的零件已投入实际生产,实践证明:采用模具型面补偿的方法进行回弹控制是切实可行的。 相似文献
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冲压零件的回弹会严重影响零件的形状和尺寸精度。通过对模具型面进行调整,从而去除回弹造成的形状误差是目前常用的一种手段。但是这种方法的模具型面设计工作量很大。文章在能量法的基础上,提出了一种预测任意截面形状的回转体零件回弹量的算法。该算法具有较快的计算速度,适用于多次迭代的补偿计算。利用该算法对半球形零件的拉深回弹进行了预测,所得结果与实验结果吻合较好。在此基础上,提出了一种位移调整的算法,通过在回弹预测量的反方向对模具型面进行补偿,可以自动获得补偿后的模具型面。实际计算结果表明,该算法具有较快的迭代速度,对一般形状的回转体零件可以在2次迭代后获得较高的零件精度。 相似文献
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模面几何修正的回弹补偿方向分析 总被引:3,自引:0,他引:3
精确回弹预测的目的是通过数值回弹模拟来修正模面,使得回弹后零件与设计的产品一致,因此,在回弹预测的基础上进行基于数值模拟或逆向工程的模面补偿和工艺调整,甚至修改成形方案和模具结构,仍然是当前降低回弹的主要措施。文章对模面几何补偿方法进行了阐述,对其应用特点、精度和效率进行了系统的对比分析,结果表明,在以转动为主导回弹的情况下,法向补偿具有很高的精度,但运行计算时间较长;在回弹存在大平移的情况下,连线方向补偿则精度较高,且算法简单;而Z向反向补偿法虽然具有算法简单、计算效率高的优点,却不能很好地对模面进行修正。 相似文献
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The recently developed multi-step sheet forming technology with inductive in-situ heating serves to increase the productivity and to reduce costs compared to hot stamping with furnace heating. The paper reveals the mechanisms for the flexible setting of geometric and mechanical properties such as the bending angle and strength in terms of a closed loop control. The air and die bending as representative forming processes are analyzed with respect to the mechanisms overbending, springback and thermal distortion by experimental, numerical, and analytical investigations. The mechanisms for controlling strength in carbon steels by grain refinement, grain growth and cooling rate are described. 相似文献
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为解决冲压成形的零件与原产品数据偏差较大的难题,提供了2种回弹补偿方式,即AutoForm迭代补偿与几何补偿,以某车型顶盖为研究对象,分别对2种补偿方式重构的型面进行全工序CAE分析,对比其回弹结果。AutoForm迭代补偿在全夹持状态下,局部区域的回弹量超过3 mm,几何补偿方式在补偿量为6 mm时,全夹持状态下回弹量在1.5 mm以内,说明AutoForm迭代补偿不宜用于自由回弹量大的零件,采用几何补偿可以提高回弹补偿的准确性。三坐标检测试制首件的尺寸符合率为85.2%,模具状态研配到与数值模拟边界条件一致时,尺寸符合率可达96.5%,验证了几何补偿方式的有效性。 相似文献
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Springback is the main defect in U-shaped part forming, which can badly affect the shape of a part. Applying reasonable variable blankholder force in the forming process is one of the useful methods to solve this problem, but determination of the curve of blankholder force vs. punch displacement is still difficult. A method is advanced in this paper to control the forming process of a U-shaped part, by which a reasonable blankholder force curve can be easily gained. Comparing with constant blankholder force, higher forming quality can be obtained in both avoiding cracking and improving dimension accuracy. The benchmarks of the 2D draw bending problem in NUMISHEET’93 has been utilized to validate the method by FEM, and good results of springback elimination have been obtained. 相似文献
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Development of an incremental rolling process for the production of defined riblet surface structures 总被引:1,自引:1,他引:1
Viscous drag reduction on fan, compressor and turbine blades may be achieved by employing a riblet surface structure. Such
a structure assists in increasing efficiency and in reducing energy consumption in flow applications. In order to produce
riblet surface structures industrially, a new and incremental rolling process is being developed and investigated. The process
design is being determined by common airstream requirements as well as the forming mechanisms that are predominant during
the rolling process. Based on this principle, the required shape of the structured rollers is being developed. Research is
focused on the feasibility of manufacturing small riblet structures at a size of a few hundred microns. Experimental production
of different riblet geometries made from Ti-6Al-4V (WL 3.7164) provides some initial insights with respect to feasibility,
shape accuracy, surface quality, and micro structure. 相似文献
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