Aiming at the flexible 3D stretch bending with multipoint dies for the aluminum profile, the numerical simulation analysis of the bending process was carried out by ABAQUS finite element software. In the multipoint stretch bending (MPSB) process, the influence of the number of die units on the springback for the complex section profile was studied. The shape error between the forming parts and the target parts was reduced through the method of die surface modification. The results showed that the springback of the aluminum profile could reach a minimum when the number of die units was 25 under the precondition of saving cost and ensuring the quality of forming parts. In the numerical simulation, the maximum shape error of the forming parts reduced from 18.824 mm to 2.456 mm; in the test, the maximum shape error reduced from 27.26 mm to 6.03 mm through the method of die surface modification.
The ABAQUS finite element simulation software was used to simulate the flexible 3D multipoint stretch-bending (MPSB) forming process of aluminum profiles. The influence of bending angle on the section distortion was investigated. The results show that the type of rectangular section distortion during horizontal bending and vertical bending is different. The bulging rate and the depression rate increase with the increase in horizontal bending angles; when the vertical bending angle is less than 15°, the depression rate of the horizontally curved section is effectively reduced. When α is equal to 30°, β is less than 15° which can effectively reduce the depression rate caused by horizontal bending to the profile. When α is less than 30°, the depression rate which is caused by horizontal bending can be reduced through the vertical bending angle, with 5° than 15°; the vertical bending process changes the distortion pattern of the profile; the depression rate and the bulging rate increase with the increase of the vertical bending angle. Through the support vector regression and selecting the parameter group c = 1.5, g = 0.05, the distortion rate of different angles in the common range is further expanded, and the quality control curve is drawn by combining the test results and prediction results which determine the depression rate as 2%, 2.5%, and 3% processing boundary. Using this curve to predict the distortion rate of the profile is instructive in the actual processing.
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