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Tool path design system to enhance accuracy during double sided incremental forming: An analytical model to predict compensations for small/large components
Journal of Manufacturing Processes ( IF 6.2 ) Pub Date : 2020-08-28 , DOI: 10.1016/j.jmapro.2020.08.014
K. Praveen , R. Lingam , N. Venkata Reddy

Double sided incremental forming (DSIF) has potential to form complex three-dimensional sheet metal components without using component specific tooling. Forming tool deflection and sheet spring-back are significant factors contributing to the geometrical inaccuracy of DSIF components. Numerical prediction and experimental measurement of sheet spring-back is time consuming. In addition, available analytical methods to predict and compensate sheet spring-back uses theory of small deflections by neglecting the membrane effects. With increase in sheet deflection beyond its thickness, membrane forces experienced by the middle plane of sheet due to stretching significantly resists the applied transverse load. In the present work, combination of small deflection and membrane theories are used to predict and compensate sheet deflections, so that a single methodology can be used for small as well as large components. Proposed methodology is validated using experimental and numerical predictions and they are in very good agreement. Two geometries (axisymmetric, free form components) with different component openings are formed to validate the proposed predictive methodology. Results indicate there is significant improvement (maximum error is less than 800 μm) in accuracy of components formed using compensated tool paths developed using proposed model. In addition, support tool maintained contact with component throughout forming (maximum force on the support tool is less than 60 N).



中文翻译:

刀具路径设计系统,可在双面增量成型过程中提高准确性:一种分析模型,可预测小/大型零件的补偿

双面渐进成形(DSIF)可以形成复杂的三维钣金零件,而无需使用特定于零件的工具。成形工具的变形和板材的回弹是导致DSIF部件几何精度不正确的重要因素。板材回弹的数值预测和实验测量非常耗时。另外,可用的预测和补偿薄板回弹的分析方法通过忽略膜效应来使用小挠度理论。随着片材挠度的增加超过其厚度,片材中间平面由于拉伸而经受的膜力会显着抵抗施加的横向载荷。在目前的工作中,小挠度和膜理论的结合用于预测和补偿板的挠度,因此,无论大小组件都可以使用一种方法。所提出的方法论已通过实验和数值预测得到验证,并且非常吻合。形成具有不同部件开口的两个几何形状(轴对称,自由形式的部件)以验证所提出的预测方法。结果表明有显着改善(最大误差小于800 μm)使用建议模型开发的补偿刀具路径形成的零件的精度。此外,在整个成型过程中,支撑工具均与组件保持接触(支撑工具上的最大力小于60 N)。

更新日期:2020-08-28
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