Process Model for the Design of Bent 3-dimensional Free-form Geometries for the Three-roll-push-bending Process

Vatter, Peter; Plettke, Raoul

doi:10.1016/j.procir.2013.05.041

Cited by 31 publications

(15 citation statements)

References 5 publications

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“…These sweeps were then transformed into curvature distributions according to the procedure described by Vatter and Plettke. 28 For the experimentally manufactured truncated cones B–D, the resulting radius over arc length plots at the tops and bases are illustrated in Figure 23.…”

Section: Resultsmentioning

confidence: 99%

Incremental bending of conic profiles on CNC hydraulic bending machines

Frohn-Sörensen

Hochstrate

Schneider

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Sheet metal forming processes for manufacturing truncated cones can be divided into methods which use shape related tooling to produce the required form, for example, spinning and deep drawing, and processes that utilise kinematics to produce the required geometry, for example, roller, air and swivel bending. Such kinematic forming methods can achieve high degrees of forming flexibility but require process models to avoid elaborate trial and error approaches. For the incremental manufacture of cones, CNC swivel bending as yet lacks such a process model. In addition, with the current ‘state of the art’ processes, the manufactured cones exhibit geometric defects with respect to concentricity and skewing. In this study, the operation of a CNC bending machine fitted with an upper beam that can be inclined was investigated. The proposed inclination of the beam corresponds to the desired conical shape of the product. The machine was provided with a radial sheet feed mechanism (back-gauge) to feed material in even segments between bent corners thus avoiding geometric imperfections. A plasto-mechanic process model was developed to deliver the process parameters for swivel bending of specific conical geometries. The process model was validated by numerical simulations and practical bending experiments. Coarsely segmented conical shapes can be manufactured using the analytically calculated process parameters. For conical geometries, the process modifications of sequential swivel bending showed satisfactory improvements in the initial bending defects, that is, lack of concentricity and skewing. Compared with the target geometries, a tendency towards larger diameters remained in the experiments and is explained by the boundary conditions of the sequential process and if a larger number of bending increments is carried out. The present study delivers a first approach to determine the process parameters for the sequential operation of a swivel bending machine in order to provide relevant process parameters for the industrial production of conical components.

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Section: Resultsmentioning

confidence: 99%

Incremental bending of conic profiles on CNC hydraulic bending machines

Frohn-Sörensen

Hochstrate

Schneider

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…It is difficult for complex cross-sectional profiles to bend in the horizontal direction without unloading condition to meet accuracy requirements through the traditional solid die [6,7]. 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.…”

Section: Introductionmentioning

confidence: 99%

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

Liang

et al. 2020

Mathematical Problems in Engineering

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The finite element numerical simulation method was used to study the stretch-bending process of asymmetric L-section aluminum alloy profiles. The geometrical parameters of the multipoint dies (MPDs) are studied to influence the shape accuracy and springback of the L-section profile after bending. The results show that the profile curvature of the MPD after the profile is bent has a great influence on the stress-strain distribution, springback value, and shape accuracy. In order to obtain uniform stress-strain of the profile and reduce the springback and shape error, the MPD is optimized by numerical simulation analysis, which has a certain reference value of providing a theoretical basis for the rational design of the flexible stretch-bending.

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“…On one hand, with the improvement of people's living standards, low-cost and small batch production of many kinds of parts and components will be the main way of industrial manufacturing in the future [13,14]. On the other hand, it is difficult for complex cross-sectional profiles to bend in the horizontal direction and vertical direction without unloading condition through the traditional die [15,16]. But the use of the combination of the flexible multipoint forming technology and the stretch bending method can be a good solution to the 3D bending profile.…”

Section: Introductionmentioning

confidence: 99%

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

Lin

Cai

et al. 2018

Advances in Materials Science and Engineering

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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.

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Process Model for the Design of Bent 3-dimensional Free-form Geometries for the Three-roll-push-bending Process

Cited by 31 publications

References 5 publications

Incremental bending of conic profiles on CNC hydraulic bending machines

Incremental bending of conic profiles on CNC hydraulic bending machines

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

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

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