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Development of die-less single-tool multi-point plate forming technology for 3D curved shape
The International Journal of Advanced Manufacturing Technology ( IF 2.9 ) Pub Date : 2021-09-01 , DOI: 10.1007/s00170-021-07883-w
Song Wu 1, 2 , Ninshu Ma 1, 2 , Sherif Rashed 1 , Naoki Osawa 2
Affiliation  

To avoid degradation of material properties, high equipment investment, low efficiency, and potential safety issues caused by conventional technologies like line heating, multi-point plate forming, and explosive forming, a new die-less single-tool multi-point plate forming (DS-MPF) technology is proposed. In DS-MPF, a moving bar is used as a single forming tool and combined with horizontal and vertical motions relative to the plate. To reduce forming force component from the membrane stress, simple support boundary condition is preferred to avoid the plate edge being bent, trimmed, or thinning after being formed. However, this boundary may easily cause instability of the forming process and worse geometric accuracy of a formed part if an unsuitable toolpath is employed. In this paper, the forming mechanism and toolpath design principle are clarified to develop this new technology. Numerical and experimental forming case from an 8-mm SS400 steel plate into a spherical surface with a radius of curvature of 1000 mm was performed to validate the new technology and its design principle. The strain analysis of results shows DS-MPF tends to be a local forming method. The formed plate normally has local positive bending strain at the tool-contacted area and limited negative bending strain at the tool-uncontacted area between adjacent strokes. Forming a 3D curved shape with high geometric accuracy in DS-MPF can be achieved with appropriate control of the local bending strain produced in each stroke, stroke position, and forming sequence.



中文翻译:

3D曲面无模具单刀多点板成型技术开发

为避免线路加热、多点板成型、爆炸成型等常规技术带来的材料性能下降、设备投资高、效率低、安全隐患等问题,新型无模具单工具多点板成型( DS-MPF) 技术被提出。在 DS-MPF 中,移动杆用作单个成形工具,并结合相对于板的水平和垂直运动。为了减少膜应力的成形分力,最好采用简单的支撑边界条件,以避免板边在成形后弯曲、修整或变薄。然而,如果采用不合适的刀具路径,该边界很容易导致成形过程的不稳定和成形零件的几何精度变差。在本文中,阐明了成形机制和刀具路径设计原理,以开发这项新技术。进行了从 8 毫米 SS400 钢板到曲率半径为 1000 毫米的球面成形的数值和实验,以验证新技术及其设计原理。结果的应变分析表明,DS-MPF 往往是一种局部成形方法。成形板通常在工具接触区域具有局部正弯曲应变,而在相邻行程之间的工具非接触区域具有有限的负弯曲应变。通过适当控制在每个行程、行程位置和成型顺序中产生的局部弯曲应变,可以在 DS-MPF 中形成具有高几何精度的 3D 弯曲形状。进行了从 8 毫米 SS400 钢板到曲率半径为 1000 毫米的球面成形的数值和实验,以验证新技术及其设计原理。结果的应变分析表明,DS-MPF 往往是一种局部成形方法。成形板通常在工具接触区域具有局部正弯曲应变,而在相邻行程之间的工具非接触区域具有有限的负弯曲应变。通过适当控制在每个行程、行程位置和成型顺序中产生的局部弯曲应变,可以在 DS-MPF 中形成具有高几何精度的 3D 弯曲形状。进行了从 8 毫米 SS400 钢板到曲率半径为 1000 毫米的球面成形的数值和实验,以验证新技术及其设计原理。结果的应变分析表明,DS-MPF 往往是一种局部成形方法。成形板通常在工具接触区域具有局部正弯曲应变,而在相邻行程之间的工具非接触区域具有有限的负弯曲应变。通过适当控制在每个行程、行程位置和成型顺序中产生的局部弯曲应变,可以在 DS-MPF 中形成具有高几何精度的 3D 弯曲形状。结果的应变分析表明,DS-MPF 往往是一种局部成形方法。成形板通常在工具接触区域具有局部正弯曲应变,而在相邻行程之间的工具非接触区域具有有限的负弯曲应变。通过适当控制在每个行程、行程位置和成型顺序中产生的局部弯曲应变,可以在 DS-MPF 中形成具有高几何精度的 3D 弯曲形状。结果的应变分析表明,DS-MPF 往往是一种局部成形方法。成形板通常在工具接触区域具有局部正弯曲应变,而在相邻行程之间的工具非接触区域具有有限的负弯曲应变。通过适当控制在每个行程、行程位置和成型顺序中产生的局部弯曲应变,可以在 DS-MPF 中形成具有高几何精度的 3D 弯曲形状。

更新日期:2021-09-01
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