Effect of Flexible 3D Multipoint Stretch Bending Dies on the Shape Accuracy and the Optimal Design

Abstract

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 influence of multi-point roller-dies on the shape deviation differences of profile in flexible stretch-bending forming

“…13 Due to the composition characteristics of the multipoint stretch bending die, there are contact and noncontact zones between the profile and the die, and the profile shape deviation in the contact zone and noncontact zone directly affects the forming quality of the profile. Lin et al 14 and Li et al 15 obtained that the increase of the number of dies improve the forming accuracy of the profile by changing the number of dies. But in the actual production process, the number of dies is often determined, so scientific placement of dies is an effective method to improve the forming accuracy of profiles.…”

Effect of Forming Parameters on Profile Thinning of Flexible 3D Multi-Point Stretch Bending

“…If you want to process the three-dimensional profile, you must manually twist the profile after the two-dimensional deformation. This is time-consuming and labor-intensive, and the scrap rate is extremely high [6,7]. Therefore, it is especially important to explore new processing methods to implement three-dimensional deformation of the profile.…”

Influence of the Curvature of the Multipoint Die for Flexible Multipoint Stretch Bending on the Quality of Aluminum Profile

“…For the flexible multipoint stretch bending, in addition to the influence of the process parameters on the bending and forming effect, the solid die composed of a plurality of MPD bodies also has a great influence on the forming effect. Lin et al determined the suitable number of MPDs for complex cross section profiles in stretch bending to reduce springback [8]. Zhao et al proposed a new method that can be used to predict the springback for profile with any cross section [9].…”