With the generation of both localised thermal and vibration in incremental sheet forming(ISF)by novel tool designs,rotational vibration assisted ISF(RV-ISF)can achieve significant force reduction and material softenin...With the generation of both localised thermal and vibration in incremental sheet forming(ISF)by novel tool designs,rotational vibration assisted ISF(RV-ISF)can achieve significant force reduction and material softening.However,the combined thermal and vibration softening in RV-ISF is unclear.By evaluating the similarities and differences of friction stir ISF(FS-ISF)and RV-ISF,this study develops a novel approach to decouple and quantify the thermal and vibration softening effects in RV-ISF of AZ31B-H24,providing new insights into underlying thermal and vibration softening mechanism.Experimental results reveal that in RV-ISF of AZ31B-H24 the thermal softening due to frictional heating dominates with 45∼65%of softening,while the vibration effect only contributes up to 15%of softening,from the conventional ISF,depending on the tool designs and tool rotational speed.The double-offset tool(T2)produces greater vibration softening than the three-groove tool(T3)owing to the higher vibration amplitude of the T2 tool.An increase in tool rotational speed primarily enhances thermal softening with only marginal changes to the vibration effect.Microstructural analysis suggests that with average grain size of 0.94μm at the top layer,RV-ISF with T3 and 3000 rpm is more effective for microstructure refinement than that by FS-ISF,especially on the tool-sheet contact surface,which confirms the occurrence of surface shearing.This refinement is a result of the reduced recrystallisation degree,71.8%at the top bottom layer.Compared with FS-ISF,RV-ISF can lead to not only higher geometrically necessary dislocation density,but also higher fraction of low-angle grain boundaries,indicating that softening mechanism due to localised vibration effect is resulted from the enhanced rearrangement and annihilation of dislocations.These findings contribute to new understanding of the thermal and vibration softening effects in RV-ISF of AZ31B-H24 and offer a theoretical foundation for the tool design and process optimisation.展开更多
In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath f...In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks （ANN） and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization （PSO） algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of s!oringback can be acquired using the FEM-PSONN model.展开更多
A theoretical prediction on forming limit diagram（FLD） of AZ31 magnesium alloy sheet was developed at warm temperatures based on the M-K theory. Two different yield criteria of von Mises and Hill＇48 were applied in...A theoretical prediction on forming limit diagram（FLD） of AZ31 magnesium alloy sheet was developed at warm temperatures based on the M-K theory. Two different yield criteria of von Mises and Hill＇48 were applied in this model. Mechanical properties of AZ31 magnesium alloy used in the prediction were obtained by uniaxial tensile tests and the Fields-Backofen equation was incorporated in the analysis. In addition, experimental FLDs of AZ31 were acquired by conducting rigid die swell test at different temperatures to verify the prediction. It is demonstrated from a comparison between the predicted and the experimental FLDs at 473 K and 523 K that the predicted results are influenced by the type of yield criterion used in the calculation, especially at lower temperatures. Furthermore, a better agreement between the predicted results and experimental data for AZ31 magnesium alloy sheet at warm temperatures was obtained when Hill＇48 yield criterion was applied.展开更多
A numerical method for coupled deformation between sheet metal and flexible-die was proposed. Based on the updated Lagrangian （UL） formulation, the elastoplastic deformation of sheet metal was analyzed with finite e...A numerical method for coupled deformation between sheet metal and flexible-die was proposed. Based on the updated Lagrangian （UL） formulation, the elastoplastic deformation of sheet metal was analyzed with finite element method （FEM） and the bulk deformation of flexible-die was analyzed with element-free Galerkin method （EFGM）. The frictional contact between sheet metal and flexible-die was treated by the penalty function method. The sheet elastic flexible-die bulging process was analyzed with the FEM-EFGM program for coupled deformation between sheet metal and bulk flexible-die, called CDSB-FEM-EFGM for short. Compared with finite element code DEFORM-2D and experiment results, the CDSB-FEM-EFGM program is feasible. This method provides a suitable numerical method to analyze sheet flexible-die forming.展开更多
The paper starts with a brief overview to the necessity of sheet metal forming simulation and the complexity of automobile panel forming, then leads to finite element analysis (FEA) which is a powerful simulation too...The paper starts with a brief overview to the necessity of sheet metal forming simulation and the complexity of automobile panel forming, then leads to finite element analysis (FEA) which is a powerful simulation tool for analyzing complex three-dimensional sheet metal forming problems. The theory and features of the dynamic explicit finite element methods are introduced and the available various commercial finite element method codes used for sheet metal forming simulation in the world are discussed,and the civil and international status quo of automobile panel simulation as well. The front door outer panel of one certain new automobile is regarded as one example that the dynamic explicit FEM code Dynaform is used for the simulation of the front door outer panel forming process. Process defects such as ruptures are predicted. The improving methods can be given according to the simulation results. Foreground of sheet metal forming simulation is outlined.展开更多
Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on t...Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on the design quality. A six sigma optimization method is proposed, by combining the dual response surface method （DRSM） and six sigma philosophy, to save computation cost and improve reliability and robustness of parts. Using this method, statistical technology, including the design of experiment and analysis of variance, approximate model and six sigma philosophy are integrated together to achieve improved quality. Two sheet metal forming processes are provided as examples to illustrate the proposed method.展开更多
By using the Finite Element Inverse Approach based on the Hill quadratic anisotrop-ically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The ...By using the Finite Element Inverse Approach based on the Hill quadratic anisotrop-ically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The blank shapes of three typical stampings are simulated and compared with numerical results given by the AUTOFORM software and experimental results, respectively. The comparison shows that the FASTAMP can predict blank shape and strain distribution of the stamping more precisely and quickly than those given by the traditional methods and the AUTOFORM.展开更多
Surrogate assisted optimization has been widely applied in sheet metal forming design due to its efficiency. Therefore, to improve the efficiency of design and reduce the product development cycle, it is important for...Surrogate assisted optimization has been widely applied in sheet metal forming design due to its efficiency. Therefore, to improve the efficiency of design and reduce the product development cycle, it is important for scholars and engineers to have some insight into the performance of each surrogate assisted optimization method and make them more flexible practically. For this purpose, the state-of-the-art surrogate assisted optimizations are investigated. Furthermore, in view of the bottleneck and development of the surrogate assisted optimization and sheet metal forming design, some important issues on the surrogate assisted optimization in support of the sheet metal forming design are analyzed and discussed, involving the description of the sheet metal forming design, off-line and online sampling strategies, space mapping algorithm, high dimensional problems, robust design, some challenges and potential feasible methods. Generally, this paper provides insightful observations into the performance and potential development of these methods in sheet metal forming design.展开更多
The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface qu...The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.展开更多
Metal sheet plastic deformation or forming is gener at ed through a mechanical pressure or a thermal variation. These pressure variatio ns or thermal variations can be created by a variety of means such as press form ...Metal sheet plastic deformation or forming is gener at ed through a mechanical pressure or a thermal variation. These pressure variatio ns or thermal variations can be created by a variety of means such as press form ing, hydroforming, imploding detonation and so on. According to the magnitude of the strain rates all these forming methods can be divided into quasi-static fo rming and dynamical forming. Up to now there are no reports of forming methods w ith the strain rates above 10 5sec -1, even though the exploding forming. In this article, we work on a dynamic super-speed forming method driven by lase r shock waves and advanced a novel concept of laser shock forming. The initial o bservation of the laser shock forming is done through a bugle testing with speci mens of SUS430 sheet metal, using a neodymium-glass laser of pulse energy 10J～ 3 0J and duration of 20 ns (FWHM). The investigation revealed that the plastic de formation during the laser shock forming is characterized as ultrahigh strain ra te up to 10 7sec -1. We indicate that plastic deformation increases nonlin early when the energy density of the laser varies. By investigating the hardness and residual stress of the surfaces, we conclude that laser shock forming is a combination technique of laser shock strengthening and metal forming for introdu cing a strain harden and a compressive residual stress on the surface of the wor k-piece, and the treated surface by laser shock forming has good properties in fatigue and corrosion resistance. This technique can achieve forming wit h or without mould.展开更多
In order to investigate the process of incremental sheet forming (ISF) through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model (FEM) was developed to simulate the pr...In order to investigate the process of incremental sheet forming (ISF) through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model (FEM) was developed to simulate the process and the simulated results were compared with those of experiment. The results of numerical simulations, such as the strain history and distribution, the stress state and distribution, sheet thickness distribution, etc, were discussed in details, and the influences of process parameters on these results were also analyzed. The simulated results of the radial strain and the thickness distribution are in good agreement with experimental results. The simulations reveal that the deformation is localized around the tool and constantly remains close to a plane strain state. With decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces, leading to less thinning and more homogeneous plastic strain and thickness distribution. During ISF, the plastic strain increases stepwise under the action of the tool. Each increase in plastic strain is accompanied by hydrostatic pressure, which explains why obtainable deformation using ISF exceeds the forming limits of conventional sheet forming.展开更多
It is pointed out that there was serious weakness w he n using the energy method for studying compressive plastic instability in sheet forming in the past. Where applying the deduced instability strengths to relativ e...It is pointed out that there was serious weakness w he n using the energy method for studying compressive plastic instability in sheet forming in the past. Where applying the deduced instability strengths to relativ e engineering analysis, theoretical solutions were away from practices. Its basi c reason is that simplified process in mathematical analysis of elastic bending energy was completely applied to that of plastic bending energy. Where the cambe r expressed by function of displacement normal to a plate was approximated to re alistic deflective camber, the displacement of deflected plate to compressed dir ection was neglected. With the aid of the improved instability strengths, the pr edictions on both critical buckling dimension of blank in cup deep-drawing with out blankholder through cylindrical die or conical die and the minimum blankhold er pressure to prevent buckling under constant load are universally in agreement with both experimental results and experiential data. On the bases of above-mentioned improvement, the approximate expressions for bo th the curvature and the twist used in equation of the energy of elastic bending are also ameliorated. Thus the obtained general equations for both the energy a nd the work done by internal force in plastic bending of a plate are more precis e than before. In the analyses of plastic buckling of shell with bending moment, the effect of bending moment is considered through the work done by simulative bending for ce. The method proposed in this paper can not only simplify analyses but also ge t practical result.展开更多
The formability of the material determines the amount of available deformation before failure and thus is important for the production of various structural components in industries. The workability of materiMs is com...The formability of the material determines the amount of available deformation before failure and thus is important for the production of various structural components in industries. The workability of materiMs is commonly evaluated by different forms of failure mod- els during sheet metal forming （SMF） processes. In order to provide a whole picture about the prediction models for SMF failure, necking-related formability and ductile fracture-related forma- bility studies in SMF processes are systematically summarized, the applicability and limitation of each model are highlighted, and the link between forming limit diagram and ductile fracture criterion is pointed out, Conclusions about some critical issues on failure in SMF are made.展开更多
Powdering/exfoliating of coatings and scratching galvanized steels and high strength steels （HSS）, are the main forms of surface damage in the forming of which result in increased die maintenance cost and scrap rate...Powdering/exfoliating of coatings and scratching galvanized steels and high strength steels （HSS）, are the main forms of surface damage in the forming of which result in increased die maintenance cost and scrap rate. In this study, a special rectangular box was developed to investigate the behavior and characteristics of surface damage in sheet metal forming （SMF） processes. U-channel forming tests were conducted to study the effect of tool hardness on surface damage in the forming of high strength steels and galvanized steels （hot-dip galvanized and galvannealed steels）. Experimental results indicate that sheet deformation mode influences the severity of surface damage in SMF and surface damage occurs easily at the regions where sheet specimen deforms under the action of compressive stress. Die corner is the position where surface damage initiates. For HSS sheet, surface damage is of major interest due to high forming pressure. The HSS and hot-dip galvanized steels show improved ability of damage-resistance with increased hardness of the forming tool. However, for galvannealed steel it is not the forming tool with the highest hardness value that performs best.展开更多
Prediction of forming limit in sheet metal forming is among the most important challenges confronting researchers. In this paper, a fully coupled elastic-plastic-damage model has been developed and implemented into an...Prediction of forming limit in sheet metal forming is among the most important challenges confronting researchers. In this paper, a fully coupled elastic-plastic-damage model has been developed and implemented into an explicit code. Due to the adoption of the plane stress and finite strain theories, model can predict deformation and damage of parts quickly and accurately. Also, damage initiation, propagation, and fracture in some operations are predicted and validated with experiments. It is concluded that finite strain combined with continuum damage mechanics can be used as a quick tool to predict ductile damage, fracture, and forming limits in sheet metal forming processes.展开更多
The simulation and experimental results obtained from stretching test of a commercial sheet of AA1200 aluminum alloy were compared and evaluated. Uniaxial tensile tests were carried out to obtain the required input pa...The simulation and experimental results obtained from stretching test of a commercial sheet of AA1200 aluminum alloy were compared and evaluated. Uniaxial tensile tests were carried out to obtain the required input parameters for simulation. Finite element analysis of the forming process was carried out using Abaqus/Explicit by considering von Mises and Hill-1948 yield criteria. Simulation results including punch force and strain distribution were compared and validated with the experimental results. The results reveal that using anisotropic yield criteria for simulation has a better match in both cases with the experiments.展开更多
The double-sided incremental forming(DSIF)improved the process flexibility compared to other incremental sheet forming(ISF)processes.Despite the flexible nature,it faces the challenge of low geometric precision like I...The double-sided incremental forming(DSIF)improved the process flexibility compared to other incremental sheet forming(ISF)processes.Despite the flexible nature,it faces the challenge of low geometric precision like ISF variants.In this work,two strategies are used to overcome this.First,a novel method is employed to determine the optimal support tool location for improving geometric precision.In this method,the toolpath oriented the tools to each other systematically in the circumferential direction.Besides,it squeezed the sheet by the same amount at the point of interest.The impacts of various support tool positions in the circumferential direction are evaluated for geometric precision.The results demonstrate that the support tool should support the master tool within 10°to its local normal in the circumferential direction to improve the geometric accuracy.Second,a two-stage process reduced the geometric error of the part by incrementally accommodating the springback error by artificially increasing the step size for the second stage.With the optimal support tool position and two-stage DSIF,the geometric precision of the part has improved significantly.The proposed method is compared to the best DSIF toolpath strategies for geometric accuracy,surface roughness,forming time,and sheet thickness fluctuations using grey relational analysis(GRA).It outperforms the other toolpath strategies including single-stage DSIF,accumulative double-sided incremental forming(ADSIF),and two-stage mixed double sided incre-mental forming(MDSIF).Our approach can improve geometric precision in complex parts by successfully employing the support tool and managing the springback incrementally.展开更多
Based on the Finite Element Theory of Rigid Plastic,relevant problems during plas-tic simulation on sheet metal forming were technologically studied and simplified;a simplified model of the blank holder during the dra...Based on the Finite Element Theory of Rigid Plastic,relevant problems during plas-tic simulation on sheet metal forming were technologically studied and simplified;a simplified model of the blank holder during the drawing process was established and the effects of related parameters on the forming processes were also studied.At the same time,a finite--element numerical simulation program SPID was developed.The distribution of strain and relationship of stress--stroke simulated were compared with experimented,the results are well coincided with each other.It is verified that the analytical program is reliable.展开更多
Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation a...Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.展开更多
The forming principle and deformation analysis of NC incremental sheet metalforming process as well as the process planning, experiment and key process parameters of verticalwall square box forming are presented. Beca...The forming principle and deformation analysis of NC incremental sheet metalforming process as well as the process planning, experiment and key process parameters of verticalwall square box forming are presented. Because the deformation of sheet metal only occurs around thetool head and the deformed region is subjected to stretch deformation, the deformed region of sheetmetal thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheetmetal deformation. The forming half-apex angle 9 and corner radius R are the main processparameters in NC incremental forming of vertical wall square box. According to sine law, a verticalwall square box can't be formed by NC incremental sheet metal forming process in a single process,rather, it must be formed in multi processes. Thus, the parallel line type tool path process methodis presented to form the vertical wall square box, and the experiment and analysis are made toverify it.展开更多
基金the financial support received from the UK Engineering and Physical Sciences Research Council(EPSRC)through project grants EP/W010089/1 and EP/T005254/1.
文摘With the generation of both localised thermal and vibration in incremental sheet forming(ISF)by novel tool designs,rotational vibration assisted ISF(RV-ISF)can achieve significant force reduction and material softening.However,the combined thermal and vibration softening in RV-ISF is unclear.By evaluating the similarities and differences of friction stir ISF(FS-ISF)and RV-ISF,this study develops a novel approach to decouple and quantify the thermal and vibration softening effects in RV-ISF of AZ31B-H24,providing new insights into underlying thermal and vibration softening mechanism.Experimental results reveal that in RV-ISF of AZ31B-H24 the thermal softening due to frictional heating dominates with 45∼65%of softening,while the vibration effect only contributes up to 15%of softening,from the conventional ISF,depending on the tool designs and tool rotational speed.The double-offset tool(T2)produces greater vibration softening than the three-groove tool(T3)owing to the higher vibration amplitude of the T2 tool.An increase in tool rotational speed primarily enhances thermal softening with only marginal changes to the vibration effect.Microstructural analysis suggests that with average grain size of 0.94μm at the top layer,RV-ISF with T3 and 3000 rpm is more effective for microstructure refinement than that by FS-ISF,especially on the tool-sheet contact surface,which confirms the occurrence of surface shearing.This refinement is a result of the reduced recrystallisation degree,71.8%at the top bottom layer.Compared with FS-ISF,RV-ISF can lead to not only higher geometrically necessary dislocation density,but also higher fraction of low-angle grain boundaries,indicating that softening mechanism due to localised vibration effect is resulted from the enhanced rearrangement and annihilation of dislocations.These findings contribute to new understanding of the thermal and vibration softening effects in RV-ISF of AZ31B-H24 and offer a theoretical foundation for the tool design and process optimisation.
基金Project(50175034) supported by the National Natural Science Foundation of China
文摘In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks （ANN） and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization （PSO） algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of s!oringback can be acquired using the FEM-PSONN model.
基金Project(51375328)supported by the National Natural Science Foundation of ChinaProject(20143009)supported by Graduates Innovation Project of Shanxi Province,ChinaProject(2015-036)supported by Shanxi Scholarship Council of China
文摘A theoretical prediction on forming limit diagram（FLD） of AZ31 magnesium alloy sheet was developed at warm temperatures based on the M-K theory. Two different yield criteria of von Mises and Hill＇48 were applied in this model. Mechanical properties of AZ31 magnesium alloy used in the prediction were obtained by uniaxial tensile tests and the Fields-Backofen equation was incorporated in the analysis. In addition, experimental FLDs of AZ31 were acquired by conducting rigid die swell test at different temperatures to verify the prediction. It is demonstrated from a comparison between the predicted and the experimental FLDs at 473 K and 523 K that the predicted results are influenced by the type of yield criterion used in the calculation, especially at lower temperatures. Furthermore, a better agreement between the predicted results and experimental data for AZ31 magnesium alloy sheet at warm temperatures was obtained when Hill＇48 yield criterion was applied.
基金Project(51275130)supported by the National Natural Science Foundation of China
文摘A numerical method for coupled deformation between sheet metal and flexible-die was proposed. Based on the updated Lagrangian （UL） formulation, the elastoplastic deformation of sheet metal was analyzed with finite element method （FEM） and the bulk deformation of flexible-die was analyzed with element-free Galerkin method （EFGM）. The frictional contact between sheet metal and flexible-die was treated by the penalty function method. The sheet elastic flexible-die bulging process was analyzed with the FEM-EFGM program for coupled deformation between sheet metal and bulk flexible-die, called CDSB-FEM-EFGM for short. Compared with finite element code DEFORM-2D and experiment results, the CDSB-FEM-EFGM program is feasible. This method provides a suitable numerical method to analyze sheet flexible-die forming.
文摘The paper starts with a brief overview to the necessity of sheet metal forming simulation and the complexity of automobile panel forming, then leads to finite element analysis (FEA) which is a powerful simulation tool for analyzing complex three-dimensional sheet metal forming problems. The theory and features of the dynamic explicit finite element methods are introduced and the available various commercial finite element method codes used for sheet metal forming simulation in the world are discussed,and the civil and international status quo of automobile panel simulation as well. The front door outer panel of one certain new automobile is regarded as one example that the dynamic explicit FEM code Dynaform is used for the simulation of the front door outer panel forming process. Process defects such as ruptures are predicted. The improving methods can be given according to the simulation results. Foreground of sheet metal forming simulation is outlined.
基金This project is supported by National Natural Science Foundation of China (No.50475020).
文摘Iterations in optimization and numerical simulation for the sheet metal forming process may lead to extensive computation. In addition, uncertainties in materials or processing parameters may have great influence on the design quality. A six sigma optimization method is proposed, by combining the dual response surface method （DRSM） and six sigma philosophy, to save computation cost and improve reliability and robustness of parts. Using this method, statistical technology, including the design of experiment and analysis of variance, approximate model and six sigma philosophy are integrated together to achieve improved quality. Two sheet metal forming processes are provided as examples to illustrate the proposed method.
基金Project supported by the National Natural Sciences Foundation of China(No. 50335060).
文摘By using the Finite Element Inverse Approach based on the Hill quadratic anisotrop-ically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The blank shapes of three typical stampings are simulated and compared with numerical results given by the AUTOFORM software and experimental results, respectively. The comparison shows that the FASTAMP can predict blank shape and strain distribution of the stamping more precisely and quickly than those given by the traditional methods and the AUTOFORM.
基金Supported by National Natural Science Foundation of China(Grant Nos.11572120,11172097,11302266)
文摘Surrogate assisted optimization has been widely applied in sheet metal forming design due to its efficiency. Therefore, to improve the efficiency of design and reduce the product development cycle, it is important for scholars and engineers to have some insight into the performance of each surrogate assisted optimization method and make them more flexible practically. For this purpose, the state-of-the-art surrogate assisted optimizations are investigated. Furthermore, in view of the bottleneck and development of the surrogate assisted optimization and sheet metal forming design, some important issues on the surrogate assisted optimization in support of the sheet metal forming design are analyzed and discussed, involving the description of the sheet metal forming design, off-line and online sampling strategies, space mapping algorithm, high dimensional problems, robust design, some challenges and potential feasible methods. Generally, this paper provides insightful observations into the performance and potential development of these methods in sheet metal forming design.
基金support from the National Natural Science Foundation of China(51575028)National Natural Science Foundation of China(51605258)the Fundamental Research Funds for the Central Universities of China(YWF-18-BJ-J-75)。
文摘The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.
文摘Metal sheet plastic deformation or forming is gener at ed through a mechanical pressure or a thermal variation. These pressure variatio ns or thermal variations can be created by a variety of means such as press form ing, hydroforming, imploding detonation and so on. According to the magnitude of the strain rates all these forming methods can be divided into quasi-static fo rming and dynamical forming. Up to now there are no reports of forming methods w ith the strain rates above 10 5sec -1, even though the exploding forming. In this article, we work on a dynamic super-speed forming method driven by lase r shock waves and advanced a novel concept of laser shock forming. The initial o bservation of the laser shock forming is done through a bugle testing with speci mens of SUS430 sheet metal, using a neodymium-glass laser of pulse energy 10J～ 3 0J and duration of 20 ns (FWHM). The investigation revealed that the plastic de formation during the laser shock forming is characterized as ultrahigh strain ra te up to 10 7sec -1. We indicate that plastic deformation increases nonlin early when the energy density of the laser varies. By investigating the hardness and residual stress of the surfaces, we conclude that laser shock forming is a combination technique of laser shock strengthening and metal forming for introdu cing a strain harden and a compressive residual stress on the surface of the wor k-piece, and the treated surface by laser shock forming has good properties in fatigue and corrosion resistance. This technique can achieve forming wit h or without mould.
基金Project(50175034) supported by the National Natural Science Foundation of China
文摘In order to investigate the process of incremental sheet forming (ISF) through both experimental and numerical approaches, a three-dimensional elasto-plastic finite element model (FEM) was developed to simulate the process and the simulated results were compared with those of experiment. The results of numerical simulations, such as the strain history and distribution, the stress state and distribution, sheet thickness distribution, etc, were discussed in details, and the influences of process parameters on these results were also analyzed. The simulated results of the radial strain and the thickness distribution are in good agreement with experimental results. The simulations reveal that the deformation is localized around the tool and constantly remains close to a plane strain state. With decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces, leading to less thinning and more homogeneous plastic strain and thickness distribution. During ISF, the plastic strain increases stepwise under the action of the tool. Each increase in plastic strain is accompanied by hydrostatic pressure, which explains why obtainable deformation using ISF exceeds the forming limits of conventional sheet forming.
文摘It is pointed out that there was serious weakness w he n using the energy method for studying compressive plastic instability in sheet forming in the past. Where applying the deduced instability strengths to relativ e engineering analysis, theoretical solutions were away from practices. Its basi c reason is that simplified process in mathematical analysis of elastic bending energy was completely applied to that of plastic bending energy. Where the cambe r expressed by function of displacement normal to a plate was approximated to re alistic deflective camber, the displacement of deflected plate to compressed dir ection was neglected. With the aid of the improved instability strengths, the pr edictions on both critical buckling dimension of blank in cup deep-drawing with out blankholder through cylindrical die or conical die and the minimum blankhold er pressure to prevent buckling under constant load are universally in agreement with both experimental results and experiential data. On the bases of above-mentioned improvement, the approximate expressions for bo th the curvature and the twist used in equation of the energy of elastic bending are also ameliorated. Thus the obtained general equations for both the energy a nd the work done by internal force in plastic bending of a plate are more precis e than before. In the analyses of plastic buckling of shell with bending moment, the effect of bending moment is considered through the work done by simulative bending for ce. The method proposed in this paper can not only simplify analyses but also ge t practical result.
基金financial support from National Natural Science Foundation of China through Grant U1737210
文摘The formability of the material determines the amount of available deformation before failure and thus is important for the production of various structural components in industries. The workability of materiMs is commonly evaluated by different forms of failure mod- els during sheet metal forming （SMF） processes. In order to provide a whole picture about the prediction models for SMF failure, necking-related formability and ductile fracture-related forma- bility studies in SMF processes are systematically summarized, the applicability and limitation of each model are highlighted, and the link between forming limit diagram and ductile fracture criterion is pointed out, Conclusions about some critical issues on failure in SMF are made.
基金supported by the National Natural Science Foundation of China under grant No. 50605043
文摘Powdering/exfoliating of coatings and scratching galvanized steels and high strength steels （HSS）, are the main forms of surface damage in the forming of which result in increased die maintenance cost and scrap rate. In this study, a special rectangular box was developed to investigate the behavior and characteristics of surface damage in sheet metal forming （SMF） processes. U-channel forming tests were conducted to study the effect of tool hardness on surface damage in the forming of high strength steels and galvanized steels （hot-dip galvanized and galvannealed steels）. Experimental results indicate that sheet deformation mode influences the severity of surface damage in SMF and surface damage occurs easily at the regions where sheet specimen deforms under the action of compressive stress. Die corner is the position where surface damage initiates. For HSS sheet, surface damage is of major interest due to high forming pressure. The HSS and hot-dip galvanized steels show improved ability of damage-resistance with increased hardness of the forming tool. However, for galvannealed steel it is not the forming tool with the highest hardness value that performs best.
文摘Prediction of forming limit in sheet metal forming is among the most important challenges confronting researchers. In this paper, a fully coupled elastic-plastic-damage model has been developed and implemented into an explicit code. Due to the adoption of the plane stress and finite strain theories, model can predict deformation and damage of parts quickly and accurately. Also, damage initiation, propagation, and fracture in some operations are predicted and validated with experiments. It is concluded that finite strain combined with continuum damage mechanics can be used as a quick tool to predict ductile damage, fracture, and forming limits in sheet metal forming processes.
文摘The simulation and experimental results obtained from stretching test of a commercial sheet of AA1200 aluminum alloy were compared and evaluated. Uniaxial tensile tests were carried out to obtain the required input parameters for simulation. Finite element analysis of the forming process was carried out using Abaqus/Explicit by considering von Mises and Hill-1948 yield criteria. Simulation results including punch force and strain distribution were compared and validated with the experimental results. The results reveal that using anisotropic yield criteria for simulation has a better match in both cases with the experiments.
基金supported by the National Natural Science Foun-dation of China(Nos.52075025,51975328)Project funded by China Postdoctoral Science Foundation(No.2021T140418)。
文摘The double-sided incremental forming(DSIF)improved the process flexibility compared to other incremental sheet forming(ISF)processes.Despite the flexible nature,it faces the challenge of low geometric precision like ISF variants.In this work,two strategies are used to overcome this.First,a novel method is employed to determine the optimal support tool location for improving geometric precision.In this method,the toolpath oriented the tools to each other systematically in the circumferential direction.Besides,it squeezed the sheet by the same amount at the point of interest.The impacts of various support tool positions in the circumferential direction are evaluated for geometric precision.The results demonstrate that the support tool should support the master tool within 10°to its local normal in the circumferential direction to improve the geometric accuracy.Second,a two-stage process reduced the geometric error of the part by incrementally accommodating the springback error by artificially increasing the step size for the second stage.With the optimal support tool position and two-stage DSIF,the geometric precision of the part has improved significantly.The proposed method is compared to the best DSIF toolpath strategies for geometric accuracy,surface roughness,forming time,and sheet thickness fluctuations using grey relational analysis(GRA).It outperforms the other toolpath strategies including single-stage DSIF,accumulative double-sided incremental forming(ADSIF),and two-stage mixed double sided incre-mental forming(MDSIF).Our approach can improve geometric precision in complex parts by successfully employing the support tool and managing the springback incrementally.
文摘Based on the Finite Element Theory of Rigid Plastic,relevant problems during plas-tic simulation on sheet metal forming were technologically studied and simplified;a simplified model of the blank holder during the drawing process was established and the effects of related parameters on the forming processes were also studied.At the same time,a finite--element numerical simulation program SPID was developed.The distribution of strain and relationship of stress--stroke simulated were compared with experimented,the results are well coincided with each other.It is verified that the analytical program is reliable.
基金supported by National Natural Science Foundation of China(No. 50175034).
文摘Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.
基金This project is supported by National Natural Science Foundation of China (No.50175034).
文摘The forming principle and deformation analysis of NC incremental sheet metalforming process as well as the process planning, experiment and key process parameters of verticalwall square box forming are presented. Because the deformation of sheet metal only occurs around thetool head and the deformed region is subjected to stretch deformation, the deformed region of sheetmetal thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheetmetal deformation. The forming half-apex angle 9 and corner radius R are the main processparameters in NC incremental forming of vertical wall square box. According to sine law, a verticalwall square box can't be formed by NC incremental sheet metal forming process in a single process,rather, it must be formed in multi processes. Thus, the parallel line type tool path process methodis presented to form the vertical wall square box, and the experiment and analysis are made toverify it.
